OPERATING AND SERVICE INSTRUCTIONS

FUEL PUMP FIGURE 2951 & 20007

SAFETY INSTRUCTIONS
Roper Pump Company manufactures this fuel pump for use in handling liquid
fuels for gas turbines. The controls and protective devices are a part of the
specific system and not supplied by Roper Pump Company. All instructions and
specifications for the fuel system should be read and understood before
installing and / or operating these units. No one should be allowed to operate or
maintain this equipment who has not been fully trained to work safely according
to the configuration of the system and in accordance with all applicable
government and industry regulations. Failure to heed this warning may result in
PHYSICAL DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH!

Roper Pump Company

P.O. Box 269
Commerce, GA 30529 USA

Telephone: (706) 335-5551

TeleFAX: (706) 335-5490
Email: sales@roperpumps.com
www.roperpumps.com

G12-459

Rev. June-14-2006
Good Practice:
NOTE: These are general guidelines and do not cover all possible situations.
It is the responsibility of the system integrator to apply this product properly

Plumbing:
1. The inlet pipe should be as short and straight
as possible to minimize suction pressure
losses. Excessive restrictions at the inlet can
cause cavitation resulting in poor
performance, noise, vibration, or pump
damage.
2. Slope the inlet plumbing appropriately to avoid
air pockets.
3. Plumbing weight, misalignment with the ports
or thermal expansion can exert excessive
force on the pump. Plumbing must be properly
supported and aligned with expansion joints, if
required, to minimize these forces.
4. To prevent over pressure situations, install a
relief valve as close to the pump outlet as
possible. Install the relief valve before any
shut-off valves.

Separate Pump and Drive Assemblies

Driveline Guards:
1. Assure adequate guards have been installed to
prevent personnel contacting moving components.

2. Follow all OSHA, Federal, state and local codes.

Check Alignment of Pump to Driveline:

Excessive misalignment can overload the pump input
shaft and cause premature failure. The figures below
show parallel and angular misalignments.
Mounting Base:
1. Mount the unit on a rigid, heavy base to provide
support and absorb shock. Bases should be
designed for high rigidity, not just strength.

2. The pump feet were not designed for mounting to

concrete and do not have enough contact area to
prevent concrete from failing. When mounting to
cement or concrete, use a steel base plate
(supplied by others) to distribute the mounting
stress over an area large enough to prevent the
cement from failing. The base plate should be at
least as thick as the pump feet. Grout it in place.
 Table of Contents

Section Page

1. General Description ............................................................................. 1

2. Installation ............................................................................................ 2
3. Understanding Operational Problems ............................................... 3
4. Pump Disassembly .............................................................................. 6
5. Cleaning and Inspection ..................................................................... 8
6. Pump Re-Assembly ........................................................................... 10

List of Figures
Figure No. Page

1 2951 Fuel Pump Part Locations and Nomenclature.......................... 4

2 20007 Fuel Pump Part Locations and Nomenclature........................ 5
3 Faceplate Disassembly Details .......................................................... 7
4 Typical Carbon Wearplate Installation ............................................. 10
5 Pump Case View Facing Inlet Flange ............................................... 11
6 Wearplate Details............................................................................... 11
7 Pump Case View Facing Faceplate End ........................................ 12
8 Typical Figure 2951 and Figure 20007 Dimensions (all Types) ... 14

! IMPORTANT !

Roper Pump Co. fuel pumps are manufactured to extremely close tolerances.
Each part, with respect to size, flatness, and alignment has been inspected
numerous times with precision instruments. Highly trained personnel assemble
the units and test them using specially designed equipment under conditions
within the specified requirements. This handbook is to acquaint you with the
installation, operation and service of Figure 2951 and 20007 pumps. Do not
attempt any operation not outlined in this handbook.
1. General Description

This operating and service instruction manual applies to Figure No. 2951 and 20007
fuel pumps. The pumps are designed to provide high-pressure fuel delivery.

The Figure 2951 and 20007 pumps are similar in construction, size and appearance.
They differ in rated capacity and internal construction details. See Table A below.

Wear Plate Rated Pressure Rated Speed Rated Flow

Figure Type Construction (PSI) (RPM) (GPM)
4 Bronze Composite
2951 8 Carbon 1000 1800 50
Composite
2 Bronze Composite
20007 3 Carbon 1500 3600 60
Composite

Table A

The 2951 and 20007 as designed are positive displacement, gear type pumps.
Each gear is supported by long life roller bearings with wear resistant thrust bearing
plates. The bearing plates are manufactured of either bronze or carbon composite
material as noted in Table A.

The pumps are driven by a separate drive shaft supported by a sealed ball bearing
assembly. This shaft is internally splined to the drive gear of the pump. A stationary
mechanical seal operates against a precisely machined surface on the end of the
drive gear shaft to provide a leak free assembly. The drive shaft seal and support
bearing can be serviced without complete disassembly of the pump.

2951 and 20007 fuel pumps accept 1-1/2-inch nominal SAE four bolt flanges for
plumbing connections. The pumps rotate in a clockwise direction as viewed from
the drive shaft.

Performance testing prior to shipment has verified operating pressure up to full flow
is within limits established by the turbine manufacturer. Hydrostatic leak testing is
also performed. Upon completion of testing, each fuel pump is flushed with rust
preventative oil to minimize the possibility of corrosion during shipment and
installation.

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2. Installation

1. Remove any anchoring bolts securing the fuel pump to the crate.

2. Lift the fuel pump out of the crate by attaching a lifting hook or sling. Fuel pump
weight is approximately 200 lbs.

3. Clean the external surfaces of the unit with all protective plugs and covers in
place. Do not remove the protective covers until the unit is ready to be installed.

4. This pump can accommodate either flange or foot mounting. Secure the pump
as appropriate for on-site requirements

5. Once mounted, the unit is ready for piping connections. Do not remove the
protective plugs until just prior to connecting the piping in order to prevent foreign
particles from entering the inlet and discharge ports.

6. Piping support should be installed to prevent piping loads from being imposed on
the fuel pump.
®
7. Do not use Teflon tape when making piping connections. Use care in
attaching the fittings in order to prevent damage to the housings or stripping of the
threaded connections.

8. If a drive coupling is to be installed, follow coupling manufactures’ instructions for

installation and proper alignment.

Important: Roper Pump Co. recommends a fuel system flushing is accomplished to

remove all foreign particles, dirt, water, weld slag, and other contaminants prior to
installation of the fuel pump.

®
Teflon is a registered trademark of E.I. duPont de Nemours, Inc.

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3. Understanding Operational Problems

Extremely close tolerances are used during the manufacturing of this product.
These tolerances are required because the internal workings of this fuel pump rotate
very close to each other for high operating efficiency. A small amount of dirt or
corrosion in the pump can prevent operation as intended.

Most problems are a result of the entry of foreign particles such as by-products of
combustion, water, dirt, rust, weld slag, etc., which may cause the fuel pump to
corrode or seize. Additional problems may be caused by rapid changes in fuel
temperature.

 Corrosion Although most rotating parts are made of corrosion resistant

material, some parts can still be attacked by corrosive elements in the fuel.
Corrosion causes more fuel pump failures than any other failure mechanism.

 Filtration Proper filters should be used and maintained on the fuel system at all
times to prevent seizing of the flow divider. Roper Pump Co. recommends that
5-micron nominal filters be used in the system.

 Temperature Changes Extreme temperature differentials between heated and

unheated fuels can cause a sudden expansion of intricate parts when switching
to a heated fuel. This can cause the fuel pump to fail depending on how fast the
fuel switch is made and how tight the internal clearances are. As a minimum,
Roper Pump Co. suggests that fuel changeovers from unheated to heated fuels
be extended over several minutes to allow internal components to gradually
expand with temperature.

4. Pump Disassembly

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Refer to Figure 1 (pg. 13) and Figure 2 (pg.14) to identify and locate parts as
noted below.

Items denoted <italics> refer to additional parts for Figure 20007 pump assemblies.

1. Disconnect the inlet and discharge plumbing from the pump. Remove the pump
(Flange or base mounted.) and place unit on a clean and secure worktable.
Remove any couplings attached to the pump and drain the pump of operating
fluids before beginning disassembly.

2. Check pump assembly for freedom of rotation. Inspect exterior surfaces for
corrosion, missing parts and evidence of improper operation. Record all
discrepancies for later referral. Match mark parts and assemblies with a grease
pencil or other suitable marking media.

3. Remove the large retaining ring (12) from the mounting adapter (14). Separate
the drive shaft (11) from the pump assembly by pulling sharply outward on the
drive shaft. The ball bearing (13) remains attached to the drive shaft (11) <as
does the flinger (41)>.

4. Remove retaining ring (9) from drive shaft.

5. Separate the ball bearing from the drive shaft with the use of an appropriate
press and mandrels. Discard the ball bearing. <Remove the flinger (41) and
o-ring (40). Discard the o-ring.>

6. Match mark the mounting adapter (14) to the backplate (35). Remove nine 1/2-
inch socket head capscrews (3) and (8) from the mounting adapter (14), noting
the position of the six longer (3) [The 3-1/4-inch long capscrews (8) locate in the
bottom three positions in the mounting adapter (14).] capscrews for re-
installation later.

7. Tap the mounting adapter (14) with a soft-faced mallet to separate from the
backplate (35).

8. Remove six 3/8-inch hex head capscrews (15) from the seal retainer (7).
Remove the seal retainer (7), <washer> (39), mechanical seal (16) and o-ring
(17) from the pump assembly. Discard the o-ring and mechanical seal.

7. Match mark the backplate (35) to the case (21). Remove two 1/2-inch socket
head capscrews (5) and four 1/2-inch hex head capscrews (38) from the
backplate (35). Lightly tap the backplate (35) with a soft-faced mallet and
separate from the case (21). Remove and discard gasket (18).

8. Match mark the faceplate assembly (31) to the case (21). Remove twelve 1/2-
inch hex head capscrews (29) and (34) from the faceplate assembly (31). [The
1/2-inch hex head bolts with drilled heads locate in the lower four positions of the

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 faceplate assembly (31).] Lightly tap the faceplate (31) with a soft-faced mallet
to separate the assembly from the case (21). Remove and discard gasket (18)
®
and Teflon o-ring (36).

9. Refer to Figure 3 below. Support the faceplate assembly (31) on an arbor press
(or equivalent) with the pistons (28) facing upward. Place a rectangular bar
across the piston (28) faces and spacers (26). Center the ram of the press on
the rectangular bar and lower the ram until the bar is trapped between the press
and the pistons (28). With a regulated air nozzle, apply air pressure to the
pressure-loading port machined between the two pistons (28). Slowly raise the
press ram while maintaining air pressure until the piston assemblies are free
from their respective bores. Remove the pins (32), springs (30) and discard the
piston o-rings (27).
PRESS RAM
AIR NOZZLE
RECTANGULAR
BAR

PISTONS (28)

PRESSURE
LOADING PORT

SPACER (26)

FACEPLATE
ASSEMBLY (31)

FIGURE 3

12. Remove the rectangular spacer plates (26) and dowel pins (37) from the case
assembly (21).

13. With a soft-faced mallet, alternately tap the roller bearing sets (25) < spacers
(42)> to begin driving the roller bearings (25), drive gear and shaft (22), idler
gear and shaft (34), wearplates (19) & (24), and U-rings (20) out as a unit.
Continue alternately tapping the parts until clear of the case (21).

NOTE: Mark the roller bearings (25), gears (22) & (34) and wearplates (19) &
(24) during disassembly to assure they are re-assembled in the same
position as removed.

NOTE: 2951 Type 8 and 20007 Type 4 pumps with carbon composite wear
plates do not utilize the U-ring (20) seal.

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5. Cleaning and Inspection

1. Thoroughly clean all parts with a suitable solvent and blow dry. Nylon or soft
wire brushes may be used to remove loose paint, dirt, etc. as necessary. Blow
any loose bristles and foreign material out of the pump with high-pressure air.
Assure all ports and fluid passages are clear of fuel residue, carbon build-up,
rust, etc. Exterior casting surfaces may be sandblasted after masking all
internal areas and ports of the pump. Do not sandblast gears, bearings, shafts
or any internal machined surfaces.

2. Drive Shaft

i. Check the shaft for cracks. Pay particular attention to the base of the gear
splines, retaining ring grooves and the base of the keyway. Non-
destructive inspection methods may be utilized for definitive inspection
results. Crack indications in any area of the drive shaft require
replacement.
ii. Inspect the seal and ball bearing areas of the shaft for evidence of over-
heating (bluing) and circumferential scratches or grooves. Minor
scratches and discoloration may be polished out with crocus cloth or very
fine emery paper.
iii. Sharp edges along the keyway and spline may be smoothed with a fine
India stone.
iv. Inspect the shaft for excessive corrosion and pitting. High spots and
minor roughness can be polished out with crocus cloth or very fine emery
paper.

3. Inspect the backplate, seal retainer and mounting adapter for condition.
Remove surface corrosion, fuel build-up, dirt, etc. Clean all bolt and dowel holes
of foreign material. High spots on machined faces may be smoothed with a fine
India stone.

4. Clean and inspect the piston bores in the faceplate. Remove foreign material
with a soft bristle brush and compressed air. Check for nicks and scratches in
the piston bores and polish as necessary with crocus cloth or very fine emery
paper.

Inspect the machined surface of the faceplate and piston spacers for condition.
Remove high spots with a fine India stone.

5. Check the gear bores in the case for cleanliness, corrosion and general
condition. Fine scratches may be polished with crocus cloth or fine emery
paper. Deep circumferential gouges, scratches or corrosion pitting require
replacement of this part.

6. Examine roller bearing (25) races, cages and rollers for wear, pitting, burnishing
or evidence of overheating. Excessive wear, damage or corrosion requires
replacing the roller bearing sets.

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7. Inspect the gear and shafts for nicks, cuts and cracks. Check the gear trunnions
for corrosion pitting and wear in the bearing areas. Examine the gear teeth for
evidence of overheating and wear.

Minor nicks and cuts on the gear teeth may be smoothed with a fine India stone.
Evidence of overheating, excessive wear or corrosion and any crack indications
require replacement of the gear and shaft. The gears must be replaced as a
set.

8. Inspect the wearplates for excessive wear, heat damage and security of the
overlay material (bronze or carbon). If heat damage is evident or the overlay
material is loose (steel backing exposed) or cracked, replace the wearplates as
a set.

Note for the 2951 Type 8 pump only: The gears, roller bearings and carbon
wearplates are matched at the factory and
must be replaced as a set.

9. Clean and inspect all attaching hardware for condition. Replace if corroded or
damaged. Internal threading may be repaired with the appropriate thread
chasers.

6. Pump Re-Assembly

®
Note: An assembly lubricant (Lubriplate #115 or equivalent.) is used for
all o-rings and seals. Light oil may be applied to the gears and
bearings as an aid in assembly.
Replace all o-rings, mechanical seals and bearings during repair.
Refer to Figure 1, Figure 2, Figure 4 and Section 4 “Pump
Disassembly” for re-assembly.
Items denoted <italics> refer to additional parts for Figure 20007 pump assemblies.

1. Clean and replace all parts as required by condition or requirement.

Demagnetize any parts exhibiting residual magnetism.
NOTE: The correct orientation of the wearplates with the pump case is critical to the
proper operation of the pump. Incorrect installation of the wearplates will
result in severe damage to the pump.

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2. Identify the faceplate and backplate ends of the case by referring to Figure 5.
Install one set of bronze wearplates (19) with a u-ring (20) into the case from the
backplate end. Position the wearplates so the pressurizing holes are adjacent to
the discharge hole (See Figure 6 and Figure 7.) and facing toward the center of
the pump.
Note: For 2951 Type 8 and 20007 Type 4 pumps, carbon wearplates (19) are
positioned similarly with the machined notches facing inward (See Figure
4 and Figure 6.). U-rings are not utilized when carbon wearplates are
installed.

FIGURE 4 – Typical Installation of ®Carbon Wearplates

Lubriplate

®
Lubriplate is a registered trademark of Fiske Brothers Refining Company.

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 “B” Denotes Backplate End
“F” Denotes Faceplate End

FIGURE 5 –Pump Case

View Facing Inlet Flange of Pump Case

Pressurizing holes positioned

toward discharge hole facing
inward.

Position machined
grooves facing
inward.

Bronze Type Carbon Type

FIGURE 6 - Wearplates
9
 Inlet Port Flange
Discharge Port Flange

Relief machined
Discharge hole, this with inlet holes.
side only. Pressurizing These holes go
holes in bronze through both ends
wearplates must be of the case.
positioned toward this
side facing the center of
the pump.

FIGURE 7 – Pump Case

View From Faceplate End

3. Slide one set of roller bearings (25) from the backplate end into the case (21)
until contact is made with the previously installed wearplates (19). Continue
pushing the bearings and wearplates into the bore until the bearings are flush
with the end of the case. <For 20007 pumps: after installing one set of roller
bearings (25) into the case (21), additionally push one set of spacers (42)
into the bores until flush with the end of the case (21).>
4. From the faceplate end of the case, carefully slide the idler gear and shaft (33)
into the bore until contacting the wearplate (19). Repeat for the drive gear and
shaft (22).
5. Install the second set of wearplates (24) and u-ring (20) assuring the
pressurizing holes (bronze type only) or machined grooves (carbon type) are
facing the discharge hole and facing toward the gear faces.

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6. Insert the second set of roller bearings (25) flush with the faceplate end of the
case (21). <Install the remaining set of spacers (42) until flush with
faceplate end of the case (21).>
®
7. Refer to figure #2. Insert a Teflon o-ring (36) into the pressure loading port
located in the faceplate assembly (31). Re-install two 1/2-inch long x 1/4-inch
diameter dowel pins (37) into the faceplate [if removed]. Install two piston
springs (30) into the respective piston bores. Lubricate and install new o-rings
(27) on the pistons (28) and insert the pistons into the faceplate bores.
8. Generously lubricate the pins (32) and spacers (26) and place in position on the
faceplate (31). Assure an adequate amount of assembly lubricant is applied
surrounding the pressure balancing spacers to hold them in place during re-
assembly.
9. Refer to figure #5. Place a new gasket (18) on the faceplate end of the case
(21). Position the faceplate assembly (31) in the same position as removed and
secure with twelve 1/2-inch hex head capscrews (34) and (29).
10. Insert a new o-ring (17) into the groove located in the drive gear and shaft.
Install a new gasket (18) over the alignment dowels (4) located in the backplate
(35) end of the pump case (21). Align the backplate assembly as removed and
secure with two 1/2-inch socket head capscrews (5) and four 1/2-inch hex head
capscrews (38).
11. <Install the washer (39) over the seal retainer (16).> Slide a new mechanical
seal (16) over the seal retainer (7). Install a new gasket (6) and secure the seal
retainer to the backplate (35) with six 3/8-inch hex head capscrews (15). Align
and secure the mounting adapter (14) with nine 1/2-inch socket head
capscrews. Note: Three shorter capscrews [~3-1/4-inch] locate in the lower
three holes of the mounting adapter.
12. Slide a new ball bearing (13) in position onto the drive shaft (11) and install the
retaining ring (9). Lightly lubricate the drive shaft and insert through the
mounting adapter, the seal retainer and into the drive gear and shaft (22). Avoid
damaging the o-ring (17) installed in step #10 above. Assure the drive shaft
engages the internal splines in the drive gear completely.
13. Install the retaining ring (12). Verify free rotation of the pump assembly; correct
any discrepancies before proceeding.
14. Perform leak and functional check of pump. Apply exterior finish as required per
on-site conditions.

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FIGURE 8 - Typical Dimensions for Figure 2951 and Figure 20007 Fuel Pumps (all Types)

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FIGURE 1 – 2951 Fuel Pump Parts Nomenclature

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FIGURE 2 – 20007 Fuel Pump Parts Nomenclature

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