2x2 3x2 threaded 3x2 flanged disassembly/assembly manual · 2019. 11. 6. · 44 2 o-ring, seal...
TRANSCRIPT
RJ-DA-14 11/19
2x2
3x2 Threaded
3x2
Flanged
Disassembly/Assembly Manual
Model 2100
ROTO-JET PUMP
DISASSEMBLY/ASSEMBLY
Model 2100
Table of Contents
i
1. INTRODUCTION ............................................................................................................ 1
1.1. ROTO-JET PUMP DESIGN .................................................................................... 1
1.2. PUMP IDENTIFICATION ........................................................................................ 1
2. DISASSEMBLY/ASSEMBLY REFERENCE INFORMATION......................................... 2
2.1. TOOLS AND ASSEMBLY STANDS ........................................................................ 2
2.2. DIMENSIONAL DRAWINGS ................................................................................... 5
2.3. SECTIONAL DRAWING AND PARTS LISTS .......................................................... 8
2.4. MECHANICAL SEALS AND PARTS LIST ............................................................. 14
2.5. SEAL SHIMMING .................................................................................................. 16
3. DISASSEMBLY INSTRUCTIONS ................................................................................ 18
3.1. PREPARATION FOR DISASSEMBLY .................................................................. 18
3.2. CAUTIONS ........................................................................................................... 18
3.3. SEAL REMOVAL .................................................................................................. 19
3.3.1. 2-7/8” Type S Single Seal .............................................................................. 19
3.3.2. 3-1/2” Type SD Single/Double Seal ............................................................... 19
3.4. ROTOR ASSEMBLY REMOVAL ........................................................................... 20
3.5. ROTOR COVER AND PICK-UP TUBE REMOVAL ............................................... 21
3.6. BEARING REMOVAL ........................................................................................... 21
3.7. PEDESTAL SLEEVE REMOVAL .......................................................................... 22
4. ASSEMBLY OF ROTOR BEARING ............................................................................. 22
4.1. BEARING INSTALLATION.................................................................................... 22
4.2. PEDESTAL SLEEVE INSTALLATION .................................................................. 24
4.3. ROTOR COVER INSTALLATION ......................................................................... 24
ROTO-JET PUMP
DISASSEMBLY/ASSEMBLY
Model 2100
Table of Contents
ii
4.4. ROTOR ASSEMBLY INSTALLATION ................................................................... 24
4.5. SEAL INSTALLATION .......................................................................................... 25
4.5.1. 2-7/8” Type S Single Seal .............................................................................. 25
4.5.2. 3-1/2” Type SD Single/Double Seal ............................................................... 26
4.5.3. Seal Hub Replacement (Reference Figure 2-9) – 3-1/2” Seal Only ............... 26
4.6. PICK-UP TUBE AND MANIFOLD INSTALLATION ............................................... 27
5. ROTATING COMPONENT REPLACEMENT .............................................................. 29
5.1. ROTOR REMOVAL ............................................................................................... 29
5.2. ROTOR INSTALLATION ....................................................................................... 29
6. HYDROSTATIC PRESSURE TEST ............................................................................. 29
7. BALANCING (ROTOR ASSEMBLY) ............................................................................ 29
8. PARTS ......................................................................................................................... 30
8.1. SPARE PARTS ..................................................................................................... 30
8.2. ORDERING PARTS .............................................................................................. 30
9. MAINTENANCE RECORD .......................................................................................... 32
APPENDIX A ....................................................................................................................... 33
APPENDIX B ....................................................................................................................... 35
ROTO-JET PUMP
DISASSEMBLY/ASSEMBLY
Model 2100
2100 1
1. INTRODUCTION This manual has been prepared to assist you in understanding the construction and the correct methods of disassembly and assembly for your new Roto-Jet pump.
The Roto-Jet pump is the simplest and most reliable high pressure pumping device ever invented. The design, material and workmanship incorporated in the construction of Roto-Jet pumps makes them capable of giving long, trouble free service. The life and satisfactory service of any mechanical unit, however, is dependent upon correct application, proper installation, periodic inspection, and careful maintenance.
We urge you to read and follow all of the directions in this manual. If additional copies are required or other detailed instructions are needed, the information may be obtained upon request.
1.1. ROTO-JET PUMP DESIGN
The exclusive patented Roto-Jet pump has only two basic working parts; a rotating case and a stationary pick-up tube collector arm within the rotating case. The Roto-Jet design completely eliminates the need for packing glands, wear rings or multiple stages as used in conventional centrifugal pumps, and also eliminates the complex pistons, rods, valves, and springs required in reciprocating pumps.
The Roto-Jet operates in the following manner: Liquid enters the intake manifold and passes into the rotating case where centrifugal force increases the pressure of the liquid and at the same time its velocity is increased. The velocity of the liquid in the rotor is converted into additional pressure as it jets into the pick-up tube.
1.2. PUMP IDENTIFICATION
Roto-Jet pumps are designated by a series of letters and numbers, such as 2100B-S484. The first group, 2100A or 2100 B, designates the drive end radial bearing design. “A” is for direct drive applications and “B” is for belt drive applications. The 2100 is an indication of the basic mechanical configuration and the second group, S484, designates the pick-up tube inlet size. The pump nameplate gives both the pump model designation and the pump serial number.
Permanent records for this pump are kept by the serial number and it must, therefore, be used with all correspondence and spare parts orders. This will ensure replacement of components in the original materials of construction.
2100 2
2. DISASSEMBLY/ASSEMBLY REFERENCE INFORMATION The following are recommended disassembly and assembly instructions for your Roto-Jet pump. We urge that the instructions be read thoroughly before attempting to dismantle the unit. The component parts must be handled with care during the disassembly and assembly process. The work area should be clean and be equipped with the required tools.
Depending on the accessibility of the pump and the extent of the repair or inspection required, the pump can be dismantled in place on its foundation. However, to facilitate the disassembly procedure, it is recommended that the pump be removed from its foundation and placed securely into a position in which the pump shaft is pointed downward and the manifold is facing upward. Roto-Jet pumps offers assembly stands for mounting the unit during disassembly and assembly.
2.1. TOOLS AND ASSEMBLY STANDS Table 2-1: Recommended Tools
DESCRIPTION QTY. PART
NUMBERS
Special Tool Kit (includes items under special tools only) 1 0665222-1 Complete Tool Kit (includes special and purchased tools) 1 0665222-2
SPECIAL TOOLS
Alignment Tool – Endbell 3 0661975 Center Guide & Puller – Pick-up Tube 1 0665285 Measuring Bar (For Shimming) 1 060580635 Lifting Ring, 3x2 Manifold 1 060580638 Pin, Guide-Endplate 1 060581220 Pin, Alignment-Rotor Cover 2 0665014 Double Seal Installation Tool 1 060582341 Tool Box – 32” x 8-1/2” x 9” 1 060095050 Adapter, Torque Wrench-F/Bearing Locknut 1 060580570 Adapter, Torque Wrench-F/Bearing Locknut 1 060580571 Wrench, Pick-up Tube Nut 1 0665582-01 Pin, Alignment-Manifold 2 0665030
PURCHASED TOOLS
Eyebolt – 1/2” – 13 x 1-1/2” Lg. Shank 3 060055411 Eyebolt – 7/16” – 14x4-1/2” Lg. Shank 3 0665199 Bearing Separator-Spread 1/2” – 8 5/8” 1 060095022 Puller – 17.5 Ton, 9-1/2” 1 060095023 Torque Wrench – 20-250 Ft. Lbs., 1/2” Drive 1 0665220
2100 3
DESCRIPTION QTY. PART
NUMBERS
Torque Wrench – 100-600 Ft. Lbs., 3/4” Drive 1 0665221 Socket – 5/16 Hex Key 1/2” Drive 1 0665223 Socket – 3/8” Hex Key 1/2” Drive 1 0665224 Socket – 5/8” Hex Key 1/2” Drive 1 0665225 Eyebolt – 5/8-11 x 4-1/2 Lg. Shank 1 060055413 Protector, Shaft Puller 1 060095037 Bearing Heater (120V/60Hz) 1 060095046 Tempitstick - 150º F 1 060095047 Tempitstick - 175º F 1 060095048 Tempitstick – 200º F 1 060095049 Depth Micrometer – 0.3”, 6” Base 1 060095051 Indicator, Test-Dial .0005” 1 060095053 Magnetic Base-Test Indicator 1 060095054 Tester V-Belt Tension 1 060095057 Pin Alignment, Shaft 1 0661975 Pin, Seal Installation 1 0665286 Connector – Leg 5/8” – 18 to ¾” – 16 2 060095024 Legs, Puller – 16-1/2” 1 Pr. 060095025 Legs, Puller – 22-1/2” 1 Pr. 060095056
ACCESSORIES*
Assembly Stand-Pump Kit (Includes stand & swivel ring) 1 060580652-K1
Assembly Stand-Rotor 1 060581074 0664076-01
0665198 Grease, SRI No. 2 Cartridge 1 060080019 Ring. Swivel Hoist (D-Ring) 1 0667025
*Note: Accessories are not included with special tools or purchased tools must be ordered.
2100 4
Figure 2-1: Disassembly/Assembly Stands
CAUTION
When lifting the pump into the vertical position with or without the assembly stand a swivel hoist ring shall be used in place of
the lifting eye bolt.
2100 5
2.2. DIMENSIONAL DRAWINGS
Figure 2-2: 2100 2x2 Dimensional Drawing
2100 6
Figure 2-3: 2100 3x2 Dimensional Drawing (Threaded)
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Figure 2-4: 2100 3x2 Dimensional Drawing (Flanged)
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2.3. SECTIONAL DRAWING AND PARTS LISTS
Figure 2-5: 2100 2x2 Section Drawing
TORQUE TABLE ITEM NO. Ft/Lbs N.M.
32 240 325 58 100 135 60 40 41 63 100 135 81 450 610
2100 9
Figure 2-6: 2100 3x2 Section Drawing
TORQUE TABLE ITEM NO. Ft/Lbs N.M.
32 240 325 58 100 135 60 40 41 61 100 135 63 100 135 81 450 610
2100 10
Table 2-2: Parts List - 2100 Pump
ITEM NO.
QTY. DESCRIPTION PART NUMBER
1 1 Pick-Up Tube Kit (see Notes 1 and 3) S-266 17-4 PH 0665156-KIT D-266 17-4 PH 0665280-KIT S-375 17-4 PH 0664951-1KIT D-375 17-4 PH 0665281-KIT S-484 17-4 PH 0664949-1KIT D-484 17-4 PH 0665282-KIT S-600 17-4 PH 0664885-1KIT D-600 17-4 PH 0664818-1KIT
14 1 Bearing Cap 0664905 17 1 Bearing Pedestal/Case Grease Lube 0664855 26 1 Endbell 0664887-1 29 1 Seal Hub (Type SD Seals Only) 0665170 32 4 Capscrew, Socket Head (Manifold) 42577 33 1 Plug, Manifold (Flanged Only) DI
Plug Manifold (Flanged Only) SST 0665110
0665110-1 36 1 Manifold 2 x 2 Threaded
2-7/8” Type S Seal DI 2-7/8” Type S Seal SST Manifold 3 x 2 Flanged 2-7/8” Type S Seal DI 2-7/8” Type S Seal SST 3-1/2” Type SD Seal DI 3-12” Type SD Seal SST Manifold 3x2 Threaded 2-7/8” Type S Seal DI 2-7/8” Type S Seal SST 3-1/2” Type SD Seal DI 3-1/2” Type SD Seal SST
0664869
0664869-1
0664939 0664939-1 0664980
0664980-1
0665018 0665018-1 0665533
0665533-1 37 1 Serial Number Plate 0665586 38 As
Required Bearing Shim 0664924
39 1 Eyebolt 0656866 42 2 Pipe Plug 060067738 43 1 Drive Shaft Key 060076024 44 2 O-ring, Seal (Type SD Seals Only) 060083941 48 1 O-ring, Manifold Plug (Flanged Only) 060083683 49 1 O-ring, PUT 41396 50 1 O-ring, Manifold (Type SD Seals Only) 060083913 51 1 O-ring, Seal Hub (Type SD Seals Only) 060083663 58 3 Capscrew, Socket Head (Endplate) 35705 60 4 Capscrew, Socket Head (Bearing Cap) 42021 61 4 Capscrew, Socket Head (Manifold Plug) (Flanged Only) 38361
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ITEM NO.
QTY. DESCRIPTION PART NUMBER
63 12 Capscrew, Socket Head (Endbell) 38361 65 4 Screw, Drive 060093116 69 1 O-ring, Seal Mating Ring (Type SD Seals Only) 060083940 70 1 Seal Plate (Type SD Seals Only) 0665167 71 4 Capscrew, Seal Plate (Type SD Seals Only) 0665540 72 9 Capscrew, Seal Hub (Type SD Seals Only) 0665541 73 1 Warning Plate – Direct Drive
Warning Plate – Belt Drive 0665538 0665539
75 Var. Seal See Seal Section 76 1 Seal Spacer (Type SD Seals Only) 0656253 77 1 Pin, Seal Spacer (Type SD Seals Only) 060084318 78 1 Seal Mating Ring See Seal Section 81 1 Nut, Lock PUT 0666615-1 84 1 Excluder 060079425 91 1 Retaining Ring (Type SD Seals Only) 0665293 92 Var. Pin, Anti-rotation See Seal Section 93 1 Seal Flush Ring (Type S Seals Only) (see Note 2) 0666228 100 1 Sleeve, Bearing 0665134 101 2 Grease Fitting V1714 105 1 Warning Plate – Operating Instructions 0665535 127 1 O-ring, PUT Nut, Nitrile
O-ring, PUT Nut, Viton 58218
0662499-128 128 2 Pin, Aligning PUT 02412 145 1 Friction Ring 0666227
Notes: (1) Standard Units are 17-4 PH. Contact factory representative for optional metallurgy.
(2) Item 93 is supplied in pumps with single type S seals with a seal flush.
(3) Pick-Up Tube kits include the pick-up tube and friction ring (Item 145).
2100 12
Figure 2-7: 2100 Rotor Assembly Section Drawing
TORQUE TABLE ITEM NO. Ft/Lbs N.M.
7 68 92 46 175 237 47 250 338 83 100 135
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Table 2-3: Parts List - Rotor Assembly
ITEM NO.
QTY. DESCRIPTION PART NO.
2100 BARE
BALANCED
2100A STACKED
AND BALANCED
2100B STACKED
AND BALANCED
3 1 Rotor-Ductile Iron Rotor-SST
0665137 0665137-1
X X X
4 1 Rotor Cover 2-7/8” Type S Single Seal, DI 2-7/8” Type S Single Seal, 316 SST 3-1/2” Type SD Single or Double Seal, DI 3-1/2” Type SD Single or Double Seal, 316 SST
0664862-1 0664862-2 0665178
0665178-1
X X X
5 1 Driveshaft 0665208 X X X 6 1 O-ring, Rotor 060083904 X X X 7 20 Capscrew, Socket Head (Rotor) 58325 X X X 8 2 Plug, Drain Rotor Cover, STL/Nitrile
Plug, Drain Rotor Cover, SST/Nitrile 060068656 060068677
X X X
11 1 Bearing, Rotor 060052139 X X 12 1 Bearing, Thrust 060052138 X X
13A 1 Bearing, Radial 2100A
060052138 X
13B 1 Bearing, Roller 2100B
060052243 X
15 1 Endplate 0664901 X X 23 1 Spacer Set, Bearing 0664907-01 X X 28 1 Spacer 0664922 X X 46 1 Self-Locking Nut 060081346 X X 47 1 Self-Locking Nut 060081347 X X 66 1 Wave Spring 060098225 X X 83 6 Capscrew 060088578 X X X 107 1 Grease Retainer 0664934 X X 109 1 Grease Retainer 0664935 X X 111 1 Hardened Shim 0660068 X X 133 1 Plug, Rotor STL
Plug, Rotor, SST 0665133
0665133-1 X X X
134 1 O-ring, Rotor Plug 58236 X X X
Note: The parts listed in items 3, 4, and 5, if purchased separately, must be balanced as an entire assembly.
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2.4. MECHANICAL SEALS AND PARTS LIST
Figure 2-8: 2-7/8” Type S Single Seal
Note: The seal flush ring, Item 93, is supplied on units with a seal flush only.
Table 2-4: Parts List - 2-7/8" Type S Single Seal
ITEM NO. QTY DESCRIPTION PART NUMBERS
1
Seal Kit - Pusher - Carbon vs. TC 0664975 Seal Kit - Pusher - SC vs. SC 0664975-02
Consisting of:
75 1 Seal - Pusher - Carbon 0664941 Seal - Pusher - Silicon Carbide 0665260
78 1 Mating Ring - Tungsten Carbide 0664942 Mating Ring - Silicon Carbide 0665733
49 1 O-ring, PUT 41396 92 4 Pin, Anti-rotation 0665302 127 1 O-ring, PUT Nut 58218
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Table 2-5: Parts List - 2-7/8" Type S Single Seal
Figure 2-9: 3-1/2” Type SD Single/Double Seal
Table 2-6: Parts List - 3-1/2" Type SD Single/Double Seal – 3x2 Pump
Seal Kit – Pusher – Std – Carbon vs. Tungsten Carbide, Nitrile – P/N 0665290 Consisting Of:
ITEM NO.
QTY. DESCRIPTION PART NUMBER
44 2 O-ring, Seal 060083941 49 1 O-ring, PUT 41396 50 1 O-ring, Manifold 060083913 69 1 O-ring, Mating Ring 060083940 75 2 Seal, Pusher, Carbon 060087015W 78 1 Seal Mating Ring 0665904 91 1 Retaining Ring 0665293 92 1 Pin, Mating Ring 178022 127 1 O-ring, PUT Nut 58218
2100 16
2.5. SEAL SHIMMING
Figure 2-10: 2-7/8” Type S Single Seal Shimming Diagram
Table 2-7: Type S Single Seal Shimming Chart
Number of Shims Required
Required Setting
1 2 3 4 5 6 7 8
B Inches 0.818 ---
0.804
0.833 ---
0.819
0.848 ---
0.834
0.863 ---
0.849
0.878 ---
0.864
0.893 ---
0.879
0.908 ---
0.894
0.923 ---
0.909
0.938 ---
0.924 mm 20.77
--- 20.42
21.16 ---
20.80
21.54 ---
21.18
21.92 ---
21.56
22.3 ---
21.95
22.68 ---
22.33
23.06 ---
22.71
23.44 ---
23.09
23.83 ---
23.47
NOTE: For proper bearing and seal location, dimension “B” (as shown in Figure 2-10) must be controlled. Use the shimming bar (P/N 060580635) and a depth micrometer to measure the seal height.
The seal height measurement is then subtracted from the number stamped on the measuring bar. This will give you dimension “B”. Referring to the shim chart and the box in which the measured value “B” falls. (The shimming chart is based on shims .015” thick, actual thickness may vary.)
2100 17
Figure 2-11: 3-1/2” Type SD Single/Double Seal Shimming Diagram
Table 2-8: Type SD Single/Double Seal Shimming Chart
Number of Shims Required
Required Setting
1 2 3 4 5 6 7 8
B Inches 1.232 ---
1.218
1.247 ---
1.233
1.262 ---
1.248
1.277 ---
1.263
1.292 ---
1.278
1.307 ---
1.293
1.322 ---
1.308
1.337 ---
1.323
1.352 ---
1.338 mm 31.29
--- 30.94
31.67 ---
31.32
32.05 ---
31.70
32.43 ---
32.08
32.81 ---
32.46
33.20 ---
32.85
33.58 ---
33.23
33.96 ---
33.61
34.34 ---
33.99
NOTE: For proper bearing and seal location, dimension “B” (as shown in Figure 2-11) must be controlled. Use the shimming bar (P/N 060580635) and a depth micrometer to measure the seal height.
The seal height measurement is then subtracted from the number stamped on the measuring bar. This will give you dimension “B”. Referring to the shim chart and the box in which the measured value “B” falls. (The shimming chart is based on shims .015” thick, actual thickness may vary.)
2100 18
3. DISASSEMBLY INSTRUCTIONS To disassemble the Roto-Jet pump, refer to Section 2.3. The following instructions are applicable to the pump being removed from its foundation and placed securely into a vertical position in which the pump shaft is pointed downward and the endbell is facing up.
WARNING: Before lifting the pump into the vertical position first remove the lifting eye and install the swivel hoist. When tightening the swivel hoist ring, torque to 100ft-lbs. Once the pump is re-assembled and in the horizontal position remove the swivel hoist and re-install the lifting eye. Reference APPENDIX B Drawing.
3.1. PREPARATION FOR DISASSEMBLY
(1) Disconnect the motor, lockout and tag.
(2) Block off the suction and discharge.
(3) Slack off belt tension; remove belts and pump sheave, or disconnect flex coupling.
(4) Disconnect and remove all piping from the manifold.
(5) Drain oil from the oil sump.
3.2. CAUTIONS
The following precautions are recommended to insure satisfactory pump operation after assembly.
3.2.1 Replace any o-rings that are exposed during the pump disassembly process as they lose their seal integrity and may leak.
3.2.2 Be sure all parts are free of dirt, stray metal chips, or any foreign matter and have been thoroughly cleaned.
3.2.3 All torque values given assume lubrication with anti-seize on threads and underside of capscrew heads (unless otherwise stated.) Refer to Section 2.3 for torque values.
3.2.4 All three bearings should be replaced as a set.
3.2.5 To avoid creating an out of balance condition that makes the pump susceptible to vibration damage, match mark capscrews and rotor cover relative positions for reassembly into the same positions.
3.2.6 Replacement of the rotor, rotor cover, or driveshaft will require balancing of rotating assembly and shimming of pump. See sections 6 and 8.
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3.2.7 WARNING: When lifting the pump into the vertical position with or without the use of the assembly stand a swivel hoist ring shall be used in place of the lifting eye. Reference APPENDIX B Drawing.
3.3. SEAL REMOVAL
3.3.1. 2-7/8” Type S Single Seal
3.3.1.1 Remove four socket head capscrews (61) from the manifold plug (33). Remove manifold plug. If pump has a 2x2 or 3x2 threaded manifold, skip this step and proceed to 3.3.1.2.
3.3.1.2 Using the pick-up tube locknut wrench (P/N 0665582-01), remove the pickup tube locknut (81) in the discharge port of the manifold (36) which secures the pick-up tube (1) to the manifold. (Note: Left hand threads.)
3.3.1.3 Thread the pick-up tube puller/guide (P/N 0665285) into the pick-up tube. Push or tap lightly on the pick-up tube puller/guide until the pick-up tube (1) and the pick-up tube o-ring (49) moves free of the manifold (36). Remove nut.
3.3.1.4 Remove the four socket head capscrews (32) from the manifold (36). Lift and remove manifold (36) from the endbell (26). If needed, thread two socket head capscrews (32) into the tapped holes in the manifold until the manifold comes loose. Place the manifold on a flat surface with the seal cavity facing up.
3.3.1.5 In this position, carefully remove the mechanical seal from the manifold. If necessary, use the seal puller included in the tool kit.
3.3.1.6 Using an o-ring pick, remove the mechanical seal o-ring and pick-up tube o-ring (49) and (127) from the pick-up tube (1).
3.3.1.7 Install a rubber or cloth shield between the pick-up tube (1) and the seal mating ring (78) in the rotor cover (4), to protect mating ring from damage.
3.3.1.8 Using a hand tool (P/N 0661977), remove the seal mating ring (78), replacement is necessary. No further disassembly is required. See Section 4.5 for reassembly of seal.
3.3.2. 3-1/2” Type SD Single/Double Seal
3.3.2.1 Remove four socket head capscrews (61) from the manifold plug (33). Remove the manifold plug. If pump has a threaded manifold, skip this step and proceed to 3.3.2.2.
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3.3.2.2 Using the pick-up tube locknut wrench (P/N 0665582-01), remove the pick-up tube locknut (81) which secures the pick-up tube (1) to the manifold.
NOTE: The pick-up tube locknut has left-handed threads.
3.3.2.3 Push or tap lightly on the pick-up tube locknut wrench until the pick-up tube (1) moves free of the manifold (36). Remove nut.
3.3.2.4 Insert pick-up tube puller/guide (P/N 0664830) into pick-up tube. Remove the four socket head capscrews (32) from the manifold (36). Lift and remove manifold (36) from the endbell (26). Place the manifold on a flat surface with the seal cavity facing up.
3.3.2.5 In this position, carefully remove the seal spacer (76) and mechanical seal (75) from the manifold. If necessary, use the seal puller included in the tool kit. (Note: Double seal only.)
3.3.2.6 Using an o-ring pick, remove the seal o-ring (44) from the manifold (36).
3.3.2.7 Remove the retaining ring (91), which holds the mating ring (78) in place.
3.3.2.8 Remove 4 socket head capscrews (71), then remove the seal plate (70) and seal (75) from the endbell (26).
3.3.2.9 Using a hand tool, remove the seal mating ring (78) and the mating ring o-ring (69). Carefully remove the mechanical seal (75) from the seal plate (70). Using an o-ring pick, remove the seal o-ring (44).
See Section 4.5 for reassembly of seal.
3.4. ROTOR ASSEMBLY REMOVAL
NOTE: From this point forward, it is recommended that the unit be mounted vertically with the shaft downward and the rotor upward when rotor assembly is removed.
3.4.1 Remove two of the twelve endbell socket head capscrews (63) at nine o’clock and three o’clock. Install the two endbell alignment rods (P/N 060580573) in place of the two capscrews. Remove the remainder of the socket head capscrews (63). Thread eyebolts (P/N 060055411) into three evenly spaced, tapped jackscrew holes and using a sling, lift and remove the endbell (26) from the pedestal/case.
3.4.2 Remove the driveshaftb key (43).
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3.4.3 Remove shaft slinger (84).
3.4.4 Remove the four socket head capscrews (58) which secure the endplate (15) to the pedestal/case (17).
3.4.5 Thread the three eyebolts (P/N 0665199) into three tapped holes at the periphery of the rotor cover (4). Remove the rotor assembly from the pedestal. Place the rotor assembly on the rotor assembly stand (P/N 060581074 with the rotor cover facing up.
3.5. ROTOR COVER AND PICK-UP TUBE REMOVAL
3.5.1 Match mark the position of each rotor cover capscrew (7) to their location and also the rotor to the rotor cover for easier repositioning.
NOTE: They MUST be re-assembled in the same location.
3.5.2 Remove two of the twenty rotor cover socket head capscrews (7) and install the two rotor cover guide pins (P/N 0665014). Remove the remaining eighteen socket capscrews (7). Thread three jackscrews evenly into the three tapped jackscrew holes in the rotor cover until it is released from the rotor.
3.5.3 Replace the three jackscrews with three ½” eyebolts (P/N 060055411) and remove the rotor cover (4). Remove the pick-up tube (1) and the rotor o-ring (6).
3.6. BEARING REMOVAL
3.6.1 Reinstall rotor cover (4) to the rotor (3) using the match mark from instruction 3.5.1 above. Do not install rotor o-ring. Thread 20 socket head capscrews into rotor (4) and tighten (torquing not required at this time.)
3.6.2 Thread three 7/16” eyebolts into three jackscrew holes on edge of rotor cover (4).
3.6.3 Remove rotor assembly from its stand, and place on a flat surface. Remove eyebolts from rotor.
3.6.4 Install one 5/8” eye bolt into the end of the shaft.
3.6.5 Thread three capscrews into three jackscrew holes hand tight.
3.6.6 Lift rotor assembly and with rotor end down and shaft up, place rotor assembly on assembly stand, being sure that the head of each socket head capscrew is in a ¾” dia. Hole on the outside edge of the stand. (NOTE: The holes are not located symmetrically.)
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3.6.7 Remove self-locking nut (46) using a bearing locknut torque wrench adapter (P/N 060580571), and discard locknut.
3.6.8 Remove the spacer.
3.6.9 Install the bearing separator (P/N 060095022) in an upside down position under the grease retainer. Make sure the separator is installed so it will pull on the inner bearing race. Remove the grease retainer (107), radial bearing (13A) or thrust bearing (13B), spacer set (23), and thrust bearing (12) all at once.
3.6.10 Apply bearing locknut torque wrench adapter (P/N 060580570) and remove the self-locking nut (47). Discard locknut.
3.6.11 Again, install the bearing puller, remove the rotor bearing (11) and oil slinger (19) by hand removing hardened shim (111), wave spring (66), and endplate (15).
3.6.12 Remove the six socket head capscrews (83) which secure the rotor (3) to the driveshaft (5). Only if rotor or driveshaft need replacement.
3.6.13 Mark the driveshaft (5) and the rotor (3) so that they may be reassembled with the same relative positions for balance considerations. Thread two capscrews evenly into the two tapped jackscrew holes in the driveshaft flange until the driveshaft is released from the rotor.
3.7. PEDESTAL SLEEVE REMOVAL
3.7.1 Inspect bearing sleeve (100) for wear, scratches, or gaul marks. If present, replace before reassembly.
3.7.2 Removal: Pull or tap bearing sleeve from pedestal bore using puller or brass rod.
4. ASSEMBLY OF ROTOR BEARING Note: Balancing – If any rotating components are replaced, i.e., shaft, rotor, or
rotor cover, the rotor assembly must be balanced in accordance with section 8. This also applies if wear is present in the rotor or rotor cover.
4.1. BEARING INSTALLATION
4.1.1 Install plug (133) and o-ring (134) in rotor. Install two guide pins (P/N 0661975) into rotor for shaft alignment. Heat the drive shaft bore in the rotor (3) to 140° - 160° F max. Check the temperature with a heat stick or freeze the drive shaft (5) using liquid nitrogen. Insert the driveshaft.
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Install the six socket head capscrews (83). Do not tighten the screws until the driveshaft and the rotor have reached the same temperature, then torque to 100 ft. lbs.
4.1.2 Place the endplate (15) on the shaft (5) as shown in assembly drawing (Figure 2-7). Fill the reservoir to 25% of its capacity with an approved grease. Be careful not to over lubricate! Install wave spring (66) and the hardened shim (111).
4.1.3 Heat the rotor bearing (11) to 150°-170° F. Check the temperature with a heat stick. Place the bearing on the shaft against the shoulder as shown in assembly drawing (Figure 2-7) letters up.
4.1.4 Hand pack the bearing with grease to 50% full, working grease into the cage and around the roller balls.
4.1.5 Heat the grease retainer (109) to 120°-150° F and install the self-locking nut (47). Torque to 250 ft lbs.
4.1.6 Heat the thrust bearing grease retainer (107) to 120°-150° F and install onto the shaft (5) as shown in the assembly drawing (Figure 2-7).
4.1.7 Heat the thrust bearing (12) to 150°-175° F. Check the temperature with the heat stick. Place bearing on shaft with the wide shoulder of the inner race against the shoulder of the grease retainer (107).
4.1.8 Hand pack the bearing with grease 50% full, working grease into the cage and around the roller balls.
4.1.9 Place the thrust bearing matched spacer set (23) around the shaft (5) and against the thrust bearing (12).
4.1.10 For Model 2100A: Heat the radial bearing (13A) to 150°-175° F, and place it on the shaft against the thrust bearing spacer set with the wide face of the inner race facing away from the bearing spacers.
For Model 2100B: Heat the inner race of the roller bearing (13B) to 150°-175° F and place it on the shaft against the bearing spacer. Place the outer race and roller in position over the inner race after it has completely cooled.
4.1.11 Install spacer (28) on shaft.
4.1.12 Place self-locking nut (46) on the shaft (5) and torque to 175 ft. lbs.
4.1.13 For drive bearing conversion, see Appendix A.
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4.2. PEDESTAL SLEEVE INSTALLATION Press or freeze pedestal bushing (100) using liquid nitrogen and install all the way into the bore of the pedestal (17) with the step towards the back. The face of the sleeve must be parallel to the face of the pedestal end plate machined surface to within .001 inches.
4.3. ROTOR COVER INSTALLATION
4.3.1 Install a 5/8” eyebolt into the end of the shaft (5). Remove rotor assembly from stand. Lay rotor assembly on its side. Thread the three 7/16” eyebolts (P/N 0665199) into three holes at the periphery of the rotor (3). Place rotor assembly back on the rotor assembly stand with the shaft down. Remove the three eyebolts. Note: This step is not required if rotor assembly was not removed.
4.3.2 Lubricate and install rotor o-ring (6) on the lip of the rotor (3). Place the pick-up tube (1) in the rotor. Lubricate the o-ring bore in the rotor cover (4) which engages the rotor o-ring (6).
4.3.3 Place the rotor cover (4) using three 7/16” eyebolts (P/N 0665199) on the rotor (3) with two alignment pins (P/N 0665014). Be sure all holes in the periphery of the rotor cover line up with the holes in the rotor, as the hole pattern is not symmetrical.
4.3.4 Install the twenty socket head cap screws (7) into their original rotor cover cap screw holes and tighten evenly to draw the rotor cover down. It is important that the rotor cover does not cock, as the o-ring might be damaged. Torque the cap screws to 68 ft. lbs.
4.4. ROTOR ASSEMBLY INSTALLATION
4.4.1 Install the endplate guide pin (P/N 060581220) into the holes in the endplate (15). Lift the rotor assembly by the eyebolts, and carefully slide the assembly into the pedestal. BE SURE THAT:
A) The alignment pin in the endplate (15) goes thru the corresponding hole in the pedestal (17) so that the vent holes in both pieces will be aligned.
B) The shaft does not cock and bind the bearings.
C) The eyebolts have a long enough shank so that they will clear the rotor housing after the rotor (3), rotor cover (4), and shaft (5) are in place.
4.4.2 Remove the alignment tool.
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4.4.3 Install the endplate to pedestal with three cap screws (58). Torque to 100 ft. lbs.
4.5. SEAL INSTALLATION
4.5.1. 2-7/8” Type S Single Seal
4.5.1.1 Lubricate and install seal mating ring o-ring in the hub of the rotor cover (4). Align the drive pin with the hole in the mating ring and insert the seal mating ring (78) into place. The seal mating ring should move back and forth slightly within the drive-pin hole.
NOTE: IF YOU ARE ONLY INSTALLING A PICK-UP TUBE OR SEAL, STEPS 4.5.1.2 – 4.5.1.4 & 4.5.1.6 ARE NOT REQUIRED.
4.5.1.2 For proper bearing and seal location, dimension “B” (as shown in Figure 2-10) must be controlled. Use the shimming bar (P/N 060580635) and depth micrometer to measure the seal height.
The seal height measurement is then subtracted from the number stamped on the measuring bar. This will give you dimension “B”. Referring to the shim chart (Table 2-6) find the box in which the measured value “V” falls. (The shimming chart is based on shims .015” thick, actual thickness may vary.)
4.5.1.3 Now tilt the pump from its vertical position to a horizontal position. Remove the four socket head cap screws (60) and bearing cap (14). Install the correct number of shims (38). Reinstall the bearing cap and four cap screws (60) and torque to 35 ft. lbs. Return the pump to a vertical position.
4.5.1.4 Again measure dimension “B” to be certain it is now correct.
4.5.1.5 Place a dial indicator (P/N 060095053) on the sealing face of the seal mating ring (78) and rotate the assembly by hand 360 degrees. The run out of the face must be within .001: (0.025 mm) T.I.R.
4.5.1.6 Install alignment tools (P/N 0661975) in rotor case for endbell/rotor case/pedestal alignment. Align endbell so that the Roto-Jet name is at the top. Carefully slide the endbell (26) into place. Lubricate and install the twelve endbell socket head cap screws (63) and torque to 104 ft. lbs.
4.5.1.7 Lubricate the seal o-ring (44). By hand, carefully press the mechanical seal (75) into position in the manifold (36). Care should be taken not to scratch or chip the seal face during installation.
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NOTE: The seal installation instructions (Section 4.5) are for a stationary seal arrangement. For a rotating seal, simply reverse the mating ring and seal. The mating ring (78) in the manifold and the seal (75) in the rotor cover.
4.5.2. 3-1/2” Type SD Single/Double Seal
4.5.2.1 Apply o-ring lube to new o-ring (44) and install in seal plate (70).
4.5.2.2 Apply light oil to seal cavity.
4.5.2.3 Install and seat seal (75) in seal plate (70). Caution to be taken to avoid chipping seal face.
4.5.2.4 Replace seal hub (29), if required. Reference Section 4.5.3 for seal hub replacement.
4.5.2.5 Slide seal plate (70) into endbell (26) with seal outward and drain hole to bottom of pump. Install 4 socket head cap screws (71) and tighten to 20 ft. lbs.
4.5.2.6 Slide mating ring (78) and o-ring on bug (69). Install retaining ring (91).
4.5.2.7 Clean the pick-up tube and seal cavity in manifold (36).
4.5.2.8 Lubricate manifold seal o-ring (44) and install in groove.
4.5.2.9 Install and seat seal (75) in manifold cavity (36). Caution to be taken to avoid chipping seal face. Use double seal installation tool (P/N 06058341), if required.
4.5.2.10 Install seal spacer (76), making sure to align the hole in the spacer with the pin (77) in the manifold.
4.5.3. Seal Hub Replacement (Reference Figure 2-9) – 3-1/2” Seal Only
4.5.3.1 Remove the 9 socket head cap screws (72) that attach hub (29) to rotor cover.
4.5.3.2 Remove o-ring (51) and clean mating surface on rotor cover (4) (Figure2-5).
4.5.3.3 Lubricate and place new o-ring (51) on seal hub (29). Apply light oil.
4.5.3.4 Install 9 socket head cap screws (72). Tighten to 15 ft. lbs. (20 NM).
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4.6. PICK-UP TUBE AND MANIFOLD INSTALLATION
NOTE: Before installing the manifold (36) to the endbell (26), it is very important that the mating machined surfaces of both theses parts be thoroughly cleaned.
4.6.1 Lubricate and install pick-up tube o-ring (49) and pick-up tube nut o-ring (127) into the pick-up tube (1).
4.6.2 Install two pick-up tube alignment pins (128) into the pick-up tube (1) and friction ring (145)(P/N 0666227).
4.6.3 Thread the center guide and pick-up tube puller (P/N 0665285) into the pick-up tube (1). Remember left-hand threads. Install two manifold guide pins (P/N 0665030) into two ¾” holes in the endbell (26).
4.6.4 Thread the manifold lifting tool (P/N 060580638) into the manifold discharge port. Lift the manifold (36) and lower over the center guide and pick-up tube puller and the two manifold guide pins, being very careful not to chip or damage the mechanical seal in the manifold.
4.6.5 Lower the manifold (36) until it registers on the endbell (26) with the suction to the left.
4.6.6 Remove the manifold guide pins.
4.6.7 Using the center guide and pick-up tube puller, pull the pick-up tube (1) into position in the manifold (36) being sure that the two pick-up tube alignment pins (128) are in the correct position. Remove the center guide and pick-up tube puller.
Note (1): Step 4.6.7 and 4.6.8 are best done with the pump in a horizontal position.
Note (2): Always inspect pick-up tube nut for any damaged threads or scratches, replace if necessary. Remember the pick-up tube nut has left-handed threads.
4.6.8 Thread in four ¾” socket head cap screws (32) and torque to 240 ft. lbs.
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Figure 4-1: Pick-up Tube Nut Lubrication
4.6.9 Lubricate the pick-up tube nut (81) with Molykote G-Rapid Plus on the threads and under the head (see figure 4-1), and using the pick-up tube nut wrench (P/N 0665582-01) thread the pick-up tube nut (81) into the pick-up tube (1) and torque to 450 ft. lbs.
4.6.10 For Flanged Pump Only – Install manifold plug (33) using cap screws (61) and torque to 100 ft. lbs.
4.6.11 Tilt the pump into a horizontal position and install the shaft slinger (84). Be sure that the slinger just touches the bearing cap or the bearings may overheat.
4.6.12 Rotate the driveshaft 360 degrees to make sure that the rotating assembly moves freely.
4.6.13 The pump can now be returned to service.
Lubricate threads and bottom of head with Molykote G-Rapid Plus
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5. ROTATING COMPONENT REPLACEMENT 5.1. ROTOR REMOVAL
5.1.1 Remove the six socket head cap screws (83) which secure the rotor (3) to the driveshaft.
5.1.2 Mark the driveshaft (5) and the rotor (3) so that they may be reassembled with the same relative positions for balance considerations. Thread two cap screws evenly into the two tapped jackscrew holes in the driveshaft flange until the driveshaft is released from the rotor.
5.2. ROTOR INSTALLATION Be sure the rotor plug (133) and the o-ring (134) are in place in the rotor (3). Heat the driveshaft bore in the rotor (3) to 140°-160° F max. Check the temperature with a heat stick. Insert the driveshaft aligning the before disassembly alignment marks and driveshaft flange holes with the holes in the rotor. Install the six socket head cap screws (83). Do not tighten the screws until the driveshaft and the rotor have reached the same temperature, then torque to 100 ft. lbs.
6. HYDROSTATIC PRESSURE TEST Hydrostatic pressure test cannot be performed on a fully assembled pump because of possible seal damage. Parts are hydrostatic pressure tested at the factory.
7. BALANCING (Rotor Assembly) Note: ALL ROTATING COMPONENTS MUST BE THOROUGHLY CLEAN
BEFORE ROTOR ASSEMBLY BALANCING IS DONE.
THIS SECTION PRESUMES THAT THE SHAFT (5) HAS ALREADY BEEN ASSEMBLED TO THE ROTOR (3) PER SECTION 5.2.
7.1 Rotor cover installation: Lubricate and install the o-ring (6) on the lip of the rotor (3). Lubricate the o-ring bore in the rotor cover (4) which engages the o-ring. Place the rotor cover on the rotor. Be sure all holes in the periphery of the rotor cover line up with the tapped holes in the rotor, as the hole pattern is not symmetrical. Make sure rotor cap screws are installed in same location from which they were removed. Tighten twenty rotor cover cap screws (7) to draw the rotor cover down. It is important that the rotor cover does not cock, as the o-ring might be damaged. Torque the cap screws to 68 ft. lbs.
7.2 Completely fill rotor cavity with liquid of required specific gravity. Seal off.
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7.3 Position half key in shaft and securely tape to shaft.
7.4 Two plane dynamic balance using surface A and B shown on Figure 2-7. Trim balance to ½ of the out of balance by drilling as indicated on Figure 2-7. Balance to within the following limits at 970-1000 RPM: .15 in. oz. max. per plane. Caution: Sufficient guarding should be used when balancing the rotating assembly.
7.5 Drain rotor assembly.
7.6 Remove rotor cover (4) to prepare for next assembly step. See Section 4.3.
8. PARTS 8.1. SPARE PARTS
Table 8-1: Minimum Recommended Spare Parts List
ITEM PART NO. QTY. Bearing Kit Direct Drive Belt Drive
0665214 0665215
1
Seal Kit – Single Seal Pusher - Nitrile Non-Abrasive Service 2-7/8” Carbon vs. TC
0664975
1
Seal Kit – Single – Seal Pusher - Viton Non-Abrasive Service 2-7/8” Carbon vs. TC
0664975-01
Seal Kit – Double Seal – Pusher Non-Abrasive Service 3-1/2” Carbon vs. TC Abrasive Service 3-1/2” TC vs. TC
0665290
0665290-02
Seal Kit – Double Seal – Bellows Non-Abrasive Service 3-1/2” Carbon vs. TC
0665291
Pick-up Tube Replacement Kit 0665213 1
Table 8-2: Auxiliary Equipment - Bypass Orifice
ITEM PART NO. Orifice – 3/32” 0682444 Orifice – 1/8” 0682445 Orifice – 5/32” 0682446
8.2. ORDERING PARTS
8.2.1 General – It is Roto-Jet Pump’s policy to continually improve its products. Therefore, specifications are subject to change without notice. Parts should be ordered as far in advance of their use as
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possible since circumstances beyond our control may reduce existing stock.
8.2.2 Placing Orders – The satisfactory ordering and receiving of parts is dependent upon specific and correct information supplied by the purchaser. A specification sheet for each unit manufactured is on file at the factory, and in case some special part is needed, it can be provided if the correct model and serial number is given. Many unnecessary errors and delays may be eliminated by observing the following instructions.
Your parts order should state:
1. Model and serial number of pump.
2. Part number, description, and quantity required.
3. Your company name, address and zip code clearly.
4. Specific shipping and billing instructions.
5. Date required.
With this assistance, the time required to expedite your order will be greatly reduced.
NOTE: Parts will be furnished in original materials unless specified as a material change. All material substitutions should be discussed with the factory.
8.2.3 Assistance – Should you need any assistance, contact the factory or nearest regional office listed on the back cover.
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9. MAINTENANCE RECORD
DATE SERIAL NO. MAINTENANCE RECORD BY:
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Appendix A A.1 2100 Rotor Assembly Drive Conversion. (Reference Figure 2-7)
A.2 Preparation. Remove rotor assembly per Section 3.4.
A.3 Convert from 2100B (belt drive) to 2100A (direct drive).
A.3.1 Remove self-locking nut (46) using a bearing locknut wrench adapter. Discard nut.
A.3.2 Remove the spacer (28).
A.3.3 Install the bearing separator under the thrust bearing (12) in an upside-down position. Make sure the separator is installed so it will pull on the inner race. Remove the radial bearing (13B), thrust bearing (12), and spacer set (23) and discard.
A.3.4 Heat the new thrust bearing (12) to 150°-175° F. Check the temperature with the heat stick. Place the bearing on the shaft with the wide shoulder of the inner race against the shoulder of the shaft.
A.3.5 Place the bearing spacer set (23) around the shaft (5) and against the thrust bearing so the retainer shoulders fit in place.
NOTE: The spacer is a matched set, check to be sure that both parts are matched with the same set number.
A.3.6 Heat the angular contact bearing (13A) to 150°-175° F and place it on the shaft against the bearing spacer with the wide face of the inner race facing away from the bearing spacer (23).
A.3.7 Install spacer (28) on shaft (5).
A.3.8 Screw self-locking nut (46) on the shaft (5) and torque to 175 ft. lbs.
A.3.9 Complete assembly per Section 4.2.
A.4 Convert from 2100A (direct drive) to 2100B (belt drive).
A.4.1 Repeat section A.3.1 – A.3.9, omit A.1.3.3 and A.1.3.6 and replace with A.4.2 and A.4.3.
A.4.2 Install the bearing separator under the thrust bearing (12) in an upside-down position. Make sure the separator is installed so it will pull on the inner race. Remove the angular contact bearing (13A), thrust bearing (12), and spacer set (23) and discard.
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A.4.3 Heat the inner race of the roller bearing (13B) to 150°-175° F, and place it on the shaft against the bearing spacer set (23). Place the outer race and rollers in position over the inner race (13B).
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Appendix B
Figure B-1: Alignment Tool Locations – 2x2
When using the swivel hoist, use in place of this lifting eye.
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Figure B-2: Alignment Tool Location – 3x2 Pump
Specification in this manual are subject to change without prior notification. Manual # RJ-DA-14 (11/19) 2019
For optimum service and technical assistance, please contact our factory for the distributor or representative
nearest to your project:
Trillium Flow Technologies Tel 801-359-8731 Fax 801-530-7828