Disassembly/Assembly Manual

RD11 2x2

RJ-DA-7 11/19

ROTO-JET PUMP

DISASSEMBLY/ASSEMBLY

RD11 2x2

Table of Contents

i

1. GENERAL .................................................................................................. 1

1.1. INTRODUCTION ............................................................................. 1

1.2. ROTO-JET PUMP DESIGN ............................................................ 1

1.3. PUMP IDENTIFICATION ................................................................ 2

2. DISASSEMBLY/ASSEMBLY ..................................................................... 2

2.1. GENERAL ....................................................................................... 2

2.2. RECOMMENDED TOOLS .............................................................. 3

2.3. MODEL RD11 2x2 DIMENSIONAL DRAWING .............................. 5

2.4. RD11 2x2 PUMP SECTION DRAWING ......................................... 6

2.4.1. Parts List - R11 Pump .......................................................... 7

2.5. SEAL OPTION DRAWING .............................................................. 9

2.6. SEAL REPLACEMENT PROCEDURE ......................................... 10

2.7. STAINLESS STEEL MANIFOLD REPLACEMENT ....................... 12

2.8. MAJOR COMPONENT REPLACEMENT ..................................... 15

3. HYDROSTATIC PRESSURE TESTING .................................................. 20

3.1. Manifold ........................................................................................ 20

3.2. Rotor and Rotor Cover .................................................................. 20

ROTO-JET PUMP

DISASSEMBLY/ASSEMBLY

RD11 2x2

Table of Contents Continued

ii

4. ROTOR ASSEMBLY BALANCING .......................................................... 20

5. SHIMMING .............................................................................................. 23

6. PARTS ..................................................................................................... 24

6.1. SPARE PARTS LIST .................................................................... 24

6.2. MAINTENANCE SUPPLIES ......................................................... 24

6.3. ACCESSORIES ............................................................................ 24

6.4. ORDERING PARTS ...................................................................... 25

7. MAINTENANCE RECORD ...................................................................... 26

8. APPENDIX A ……………………………………………………………………27

RD11 2x2 1

ROTO-JET PUMP

DISASSEMBLY/ASSEMBLY

Model RD11 2x2

1. GENERAL

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.

1.2. 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.

RD11 2x2 2

1.3. PUMP IDENTIFICATION Roto-Jet pumps are designated by a series of letters and numbers, such as RD11-S252. The first group, RD11, is an indication of the basic mechanical configuration and the second group, S252, designates the pick-up tube 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.

2. DISASSEMBLY/ASSEMBLY

2.1. GENERAL The following are recommended dismantling 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 dismantling 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 manifold is facing upward. Roto-Jet pumps offers assembly stands for mounting the unit during disassembly and assembly.

RD11 2x2 3

2.2. RECOMMENDED TOOLS

Item No. Description Qty Part No.

Complete Tool Kit (includes items under special tools) 1 0665203

SPECIAL TOOLS

Lock Nut Tool *** 1 0661862

Pick-Up Tube Guide *** 1 0660898

Rotor Assembly Alignment Rod 1 0661986

Manifold Guide Pin 2 0661975

Seal Installation Tool *** 1 060580624

Seal Puller *** 1 0661976

Seal Mating Ring Puller *** 1 0661977

Manifold Puller *** 1 060580638

Measuring Bar 1 060580635

Tool Box 1 060095050

Socket ¼” Hex Bit x 1-1/2” Long x 3/8” Drive 1 060095032

Hydro Test Plug 1 0665197

PURCHASED TOOLS

Socket 5/6” Hex Bit x 3/8” Drive 1 060095060

Eyebolt with Nut 3/8-16 3 0661979

Scriber 1 060095045

Bearing Heater (120V/60Hz) 1 060095046

Torque Wrench 5-80 ft-lbs. 1 060095026

Torque Wrench 30-250 ft. lbs. 1 060095027

Depth Micrometer – 0.3”, 6” Base 1 060095051

Indicator, Test Dial .0005 1 060095053

Magnetic Base – Test Indicator 1 060095054

*** Tool Requirement for Seal Replacement Only.

RD11 2x2 4

2.2.1. Assembly Stands

Item No. Description Qty Part No.

1 Pump Assembly Stand Kit (Includes stand & swivel ring) 1 060580652-K1

2 Ring, Swivel Hoist 1 0667025

Assembly stand can be used for all Roto-Jet pumps.

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.

RD11 2x2 5

2.3. Model RD-11 2x2 Dimensional Drawing

NOTES: 1. DIMENSIONS ARE NOT FOR

INSTALLATION PURPOSES UNLESS CERTIFIED.

2. PUMP SIZE, MODEL AND

SERIAL NUMBER MUST BE SPECIFIED WHEN ORDERING SPARE PARTS.

3. SUCTION AND DISCHARGE

PORTS MATE WITH STANDARD 2 NPT PIPE.

RD11 2x2 6

2.4. R11 PUMP SECTION DRAWING

TORQUE TABLE

Item No.

Ft. Lbs.

N•M

7 40 55

8 13 18

63 55 75

81 217 294

135 35 48

RD11 2x2 7

2.4.1 Parts List – RD11 Pump Item No.

Qty

Description

Part No.

Material

1 1 Pick-Up Tube S252 S338 S433 D433

0661429 0660332 0660333 0661010

17-4 PH 17-4 PH 17-4 PH 17-4 PH

3 1 Rotor (1) Ductile Iron Stainless Steel

0665004

0665004-1

DI

CF8M

4 1 Rotor Cover (1) Ductile Iron Stainless Steel

0661540

0661540-002

DI

CF8M

6 1 O-Ring, Rotor 0660372 Nitrile

7 12 Capscrew, Rotor Cover 0660335 Steel

8 2 Drain Plug, Rotor Cover Steel Stainless Steel

060068656 060068677

Steel/Nitrile SST/Nitrile

24 1 Plug, Manifold Ductile Iron Stainless Steel

060067736 060067741

DI

SST

31 1 Case, Rotor 0665513-1 Steel

63 20 Capscrew, Manifold and Back Plate 060088352 Steel

33 1 Plug, Manifold Ductile Iron Stainless Steel

060067738 060067748

DI

SST

36 1 Manifold Ductile Iron Stainless Steel

0661512

0662338-001

DI

SST

38 0-4 Shims 0665010 Brass

39 1 Eyebolt 0656866 Steel

43 1 Key, Motor, (Supplied with Motor)

44 1 O-Ring, Seal 060083779 Nitrile

49 1 O-Ring, Pick-Up Tube 0660373 Nitrile

69 1 O-Ring, Seal Mating Ring 060083625 Nitrile

75 1 Seal 0660472 316/Carbon

78 1 Seal Mating Ring 0652046-002 SST/TC

81 1 Lock Nut Pick-Up Tube 0661541 316 SST

82 1 Key, Pick-Up Tube 0661624-001 316 SST

91 1 Retaining Ring 060099130 SST

92 1 Drive Pin 0662519 S/S

93A 1 Seal Spacer (2) Steel Stainless Steel

0661552

0661552-1

Steel SST

93B 1 Flush Ring (2) 0661525 316 SST

RD11 2x2 8

2.4.1 Parts List - RD11 Pump, Continued

Item No.

Qty

Description

Part No.

Material

117 1 Coupling MTR.FR. 213TC-215TC 254TC-256TC 284TSC-286TSC 324TSC-365TSC

0665058 0665025 0665025

0665003-1

Steel Steel Steel Steel

130 1 Backplate MTR.FR. 213TC-215TC 254TC-256TC 284TSC-286TSC 324TSC-365TSC

0665057 0665519-1 0665515-1 0665517-1

DI DI DI DI

131 4 Bolt, Flange Motor 254TC-286TSC 324TSC-364TSC

58545 58467

Steel Steel

132 1 Screw, Set Coupling 0663448 Steel

133 1 Plug, Rotor Steel Stainless Steel

0665008

0665008-2

Steel SST

134 1 O-Ring, Rotor Plug 0663084-148 Nitrile

135 4 Bolt, Flange, Coupling 58466 Steel

143

AR

Shim, Case .010” Shim, Case .030” Shim Case .050”

0665800-1 0665800-2 0665800-3

Steel

219 1 Motor

SS Manifold Consisting of:

36 1 Manifold/Endbell 0663011-1 CFBM

95 1 Nozzle 0663012-1 316 SST

96 1 O-Ring 0662499-149 Viton

97 4 Capscrew, Nozzle 060088716 304 SST

* Bearing kit P/N 0661950 consists of the above noted parts.

NOTES:

(1) These parts, if purchased separately, require that the rotating assembly be balanced and pump be re-shimmed.

(2) Item 93 seal spacer supplied in standard unit, flush ring supplied in pumps

with seal flush.

RD11 2x2 9

2.5. SEAL OPTION DRAWING Table 2.5 - Seal Option Parts

Item No.

Qty

Description

Part Number:

1 Seal Kit Carbon vs. T/C (standard) Seal Kit T/C vs. T/C

0665207-CT 0665207-TT

38 0-4 Shims 0665010

44 1 O-Ring – Seal (Nitrile) 060083779

49 1 O-Ring – Pick-Up Tube (Nitrile) 0660373

69 1 O-Ring – Seal Mating Ring (Nitrile) 060083625

75 1 Seal – Pusher – Carbon Seal – Pusher – Tungsten Carbide

0660472 060754067

78 1 Seal Mating Ring – Tungsten Carbide

0652046-002

91 1 Retaining Ring – Seal (Stainless Steel)

060099130

92 1 Drive Pin – Seal Mating Ring (Stainless Steel)

0662519

MANIFOLDPICK-UP TUBE

ROTOR COVER

6938 75 93

494491

78

92

RD11 2x2 10

2.6. SEAL REPLACEMENT PROCEDURE

The following instructions are applicable to seal replacement only with the pump being in a shaft horizontal position. Refer to figure 2.4 as well as section 6.0.

2.6.1. Recommended Parts

Seal kit.

2.6.2. Recommended Special Tools

Lock Nut puller Seal Puller Pick-Up Tube Guide Seal Mating Ring Puller Manifold Guide Pins Seal Installation Tool

2.6.3. Preparations for Disassembly

2.6.3.1 Lock out and tag the driver. Disconnect power to motor if removing

pump from baseplate.

2.6.3.2 Blank off and drain the suction and discharge lines.

2.6.3.3 Disconnect and remove all piping from the manifold.

2.6.4 Cautions:

The following precautions are recommended to insure satisfactory operation of the pump after assembly.

2.6.4.1 Always replace any o-rings that are exposed during disassembly as

they can lose their seal integrity and may leak. 2.6.4.2 Be sure all parts are free from dirt, stray metal chips or any foreign

matter and have been thoroughly cleaned. 2.6.4.3 All torque values assume lubrication with molybdenum disulfide on

threads and underside of capscrew heads. Refer to figure 2.4 for torque values.

2.6.5 Disassembly:

2.6.5.1 Using the lock nut tool, unthread and remove the lock nut (81) which

secures the pick-up tube (1) to the manifold (36). Note that this is a left-hand thread.

2.6.5.2 Fully thread the pick-up tube guide into the pick-up tube (1). Tap

lightly on the pick-up tube guide until the pick-up tube clears the o-ring (49).

RD11 2x2 11

2.6.5.3 Remove the ten hex head cap screws (63) which secure the manifold (36) to the case (31). Install two manifold guide pins into two threaded holes in the case (31) at the two o'clock and ten o'clock positions.

2.6.5.4 Evenly thread two of the hex head cap screws (63) into the threaded

holes in the manifold (36) until the manifold moves free of the case (31). Carefully guide the manifold over the pick-up tube until the pick-up tube guide is cleared. Place the manifold on a flat surface with the seal (75) visible. Remove the manifold guide pins.

2.6.5.5 Remove the seal retaining ring (91) from the manifold. Grasping the

inside diameter of the seal spacer (93A) or the flush ring (93B), pull to remove the seal (75) along with the seal spacer or the flush ring. If unable to remove by hand, remove using the seal puller.

2.6.5.6 Remove the pick-up tube o-ring (49) and the seal o-ring (44). 2.6.5.7 Place a rubber protective shield between the pick-up tube (1) and the

seal mating ring (78). Remove the key (82) from the pick-up tube. 2.6.5.8 Grasping the outside diameter of the seal mating ring (78), pull to

remove. If unable to remove by hand, install the seal mating ring puller and evenly thread the two capscrews against the rotor cover (4) until the seal mating ring is free of the rotor cover. Remove shims (38) if there are any under the seal mating ring (78).

2.6.5.9 Remove the seal mating ring o-ring (69).

2.6.6 Assembly:

2.6.6.1 Lubricate and install the seal mating ring o-ring (69) in the rotor cover (4). Lubricate the seal mating ring cavity with light oil.

2.6.6.2 Carefully guide the seal mating ring (78) over the pick-up tube guide

and the pick-up tube (1). Align the hole in the seal mating ring with the driver pin (92) in the rotor cover (4). Slide the seal mating ring into place until flush against the rotor cover. Install shims (38) if needed (see Section 5.0). NOTE: The seal mating ring should rotate slightly back and forth within the drive pin hole.

2.6.6.3 Lubricate and install the pick-up tube o-ring (49) and the seal o-ring

(44) in the manifold (36). Lubricate the seal cavity in the manifold with light oil. Place the seal spacer (93A) or the flush ring (93B) in the manifold cavity.

RD11 2x2 12

2.6.6.4 Using the seal installation tool, insert the seal (75) into the manifold (36) cavity being careful not to damage the seal face. Install the retaining ring (91) into the manifold groove.

2.6.6.5 Clean seal face and the seal mating ring face. Remove protective

shield. 2.6.6.6 Being extremely careful not to damage seal or seal mating ring, install

manifold (36). Slide pick-up tube guide through manifold. Align manifold on manifold guide pins and slide into place on pedestal while holding pick-up guide centered.

2.6.6.7 Remove the manifold guide pins and seat the manifold (36) into the

case (37) by evenly torquing the ten hex head capscrews (63). Torque the capscrews to 55 ft. lbs. (75 N-M).

2.6.6.8 Using the pick-up tube guide, align the manifold (36) keyway and the

pick-up tube (1) keyway. Pull the pick-up tube past the o-ring (49) and against the manifold shoulder. Remove the pick-up tube guide.

2.6.6.9 Install the pick-up tube key (82) into the keyways. Using the lock nut tool, thread lock nut (81) into pick-up tube. Torque lock nut to 217 ft. lbs. (294 N-M). NOTE: This is a left-hand thread.

NOTE: The 1/2 inch seal drain on the manifold should not be plugged.

2.6.6.10 This completes the seal replacement procedure. The pump may be

put back into operation.

2.7 STAINLESS STEEL MANIFOLD ASSEMBLY NOZZLE AND O-RING REPLACEMENT

The following procedure should be used when the o-ring must be changed to be compatible with the fluid being pumped or the nozzle becomes damaged. This assembly is not normally disassembled. The nozzle is an interference fit in the manifold. Refer to figure 2.4.

2.7.1 Recommended Parts Nozzle (95) O-Ring, Nozzle (96)

2.7.2 Recommended Special Tools Lock Nut Tool Manifold Puller Pick-Up Tube Guide Seal Puller Manifold Guide Pins

2.7.3 Preparations for Disassembly

RD11 2x2 13

2.7.3.1 Lock out and tag driver. 2.7.3.2 Blank off and drain the suction and discharge lines. 2.7.3.3 Drain, disconnect and remove all piping from manifold.

2.7.4 Cautions

The following precautions are recommended to insure satisfactory pump operation after assembly.

2.7.4.1 Replace any o-rings that are exposed during the disassembly process

as they may lose their seal integrity and may leak. 2.7.4.2 Be sure all parts are free of dirt, stray metal chips or any foreign matter

and have been thoroughly cleaned. 2.7.4.3 All torque values given assume lubrication with molybdenum disulfide

on threads and underside of capscrew heads. Refer to figure 2.4 for torque values.

2.7.5 Disassembly

The following instructions are applicable to replacement with the pump being in a shaft horizontal position. Refer to Figure 2.4 as well as Section 6.0.

2.7.5.1 Using the lock nut tool, unthread and remove the lock nut (81) which

secures the pick-up tube (1) to the manifold (36). Note that this is a left-handed thread.

2.7.5.2 Fully thread the pick-up tube guide into the pick-up tube (1). Lightly

tap on pick-up tube guide until the pick-up tube moves free of the o-ring (49).

2.7.5.3 Install the manifold puller in manifold (36) outlet. Remove the ten hex

head capscrews (63) which secure the manifold (36) to the case (31).

2.7.5.4 Install the manifold guide pins and evenly thread two of the hex head capscrews (63) into the threaded holes in the manifold until the manifold moves free of the case. Carefully guide the manifold over the pick-up tube until the pick-up tube guide is cleared. Remove the manifold puller and place the manifold on a flat surface with the seal (75) down.

2.7.5.5 Remove the four socket head capscrews (97) that secure the nozzle

to the manifold. 2.7.5.6 Evenly thread two of the socket head capscrews (97) into the threaded

holes in the nozzle until the nozzle is released from the manifold (36).

RD11 2x2 14

2.7.6 Assembly

After the parts have been cleaned and inspected, the assembly process can be started.

2.7.6.1 Lubricate and install a new nozzle o-ring (96) in the nozzle (95)

groove. 2.7.6.2 Set the nozzle (95) into the manifold (36) with the keyway at the top.

Evenly thread all four of the socket head capscrews (97) into the threaded holes in the manifold (36). Evenly tighten the capscrews until the nozzle is pulled into position. Then torque to 47 ft. lbs. (64 NM).

2.7.6.3 Lubricate and install the pick-up tube o-ring (49) in the manifold (36). 2.7.6.4 Clean the seal (75) face and the seal mating ring (38). Install manifold

puller into the manifold (36). 2.7.6.5 Being extremely careful not to damage the seal (75) or the seal mating

ring (38), guide the pick-up tube through the manifold (36). Remove the protective shield and lower the manifold over the manifold guide pins while holding the pick-up tube guide centered.

2.7.6.6 Remove the manifold guide pins. Seat the manifold (36) to the case

(31) by evenly threading the ten hex head capscrews (63). Torque the capscrews to 55 ft. lbs. (75 NM).

2.7.6.7 Remove the manifold puller. Using the pick-up tube guide, align the

manifold (36) keyway and the pick-up tube (1) keyway. Pull the pick-up tube past the o-ring (49) and against the manifold shoulder.

2.7.6.8 Remove the pick-up tube guide. Install the pick-up tube key (82) into

the keyways. Using the lock nut tool, thread lock nut (81) into pick-up tube. Torque lock nut to 217 ft. lbs. (294 NM).

2.7.6.9 This completes the nozzle and nozzle o-ring replacement procedure

RD11 2x2 15

2.8 MAJOR COMPONENT REPLACEMENT

The following instructions are included in the event that the rotor or rotor cover needs to be replaced or other repairs are necessary. (Once installed, the coupling (117) is considered a permanent part of the motor. If the coupling should need replacing, contact the factory.) Refer to figure 2.4 as well as section 6.0. Cautions: Replacement of the rotor or rotor cover will require balancing of the rotating assembly and shimming of the pump.

2.8.1 Preparations for disassembly

2.8.1.1 Disconnect power to motor (lockout and tag). 2.8.1.2 Shut off and drain the suction and discharge lines. 2.8.1.3 Drain, disconnect and remove all piping from the manifold. 2.8.1.4 Drain rotor by removing the rotor drain plug (8) from the manifold (36).

Rotate motor (219) until the rotor cover drain plug (8) is visible through the unplugged hole in the manifold (36). Remove the rotor cover drain plug and rotate the motor until the opening is at the bottom of the case (31). Drainage will exit from the rotor drain under the case (31).

2.8.2 Cautions

The following precautions are recommended to insure satisfactory pump operation after assembled. 2.8.2.1 Replace any o-rings that are exposed during the pump disassembly

process as they lose their seal integrity and may leak. 2.8.2.2 Be sure all parts are free of dirt, stray metal chips or any foreign

matter and have been thoroughly cleaned.

2.8.2.3 All torque values given assume lubrication with molybdenum disulfide on threads and underside of capscrew heads. Refer to figure 2.4 for torque values.

2.8.2.4 When replacing pick-up tube, replace pick-up tube lock nut to avoid

attachment complication. 2.8.2.5 To avoid creating an out of balance condition that makes the pump

susceptible to vibration damage, match mark capscrew and component relative positions for reassembly into same positions.

2.8.2.6 Replacement of the rotor and rotor cover will require balancing of

rotation assembly and shimming of pump.

RD11 2x2 16

2.8.2.7 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 A Drawing.

2.8.3 Disassembly

The following instructions are applicable to the pump being removed from a foundation and mounted in a vertical or horizontal position. 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 A Drawing.

2.8.3.1 Using the lock nut tool, unthread and remove the lock nut (81)

which secures the pick-up tube (1) to the manifold (36). Note that this is a left-handed thread.

2.8.3.2 Fully thread the pick-up tube guide into the pick-up tube (1). Lightly

tap on pick-up tube guide until the pick-up tube moves free of the o-ring (49).

2.8.3.3 Install the manifold puller in manifold (36) outlet. Remove the ten

hex head capscrews (63) which secure the manifold (36) to the case (31).

2.8.3.4 Evenly thread two of the hex head capscrews (63) into the

threaded holes in the manifold (36) until the manifold moves free of the case (31). Carefully guide the manifold over the pick-up tube until the pick-up tube guide is cleared. Place the manifold on a flat surface with the seal (75) visible.

2.8.3.5 Place a protective shield between the pick-up tube and the seal

mating ring (78). Remove the key (82) from the pick-up tube keyway.

2.8.3.6 Remove the seal retaining ring (91) from the manifold (36).

Grasping the inside diameter of the seal spacer (93A) or the flush ring (93B), pull to remove the seal (75) along with the seal spacer or the flush ring. If unable to remove by hand, remove using the seal puller.

2.8.3.7 Remove the pick-up tube o-ring (49) and the seal o-ring (44).

2.8.3.8 Remove the ten hex head capscrews (63) which hold the case (31)

to the backplate (130) and remove the case.

2.8.3.9 Thread the three eyebolts (or one if horizontal) into three evenly spaced holes in the rotor cover (4). Adjust the eyebolt nuts until

RD11 2x2 17

flush against the rotor cover. 2.8.3.10 Remove the four hex flange bolts (135) that hold the rotor (3) to the

coupling (117). Evenly thread two hex flange bolts (135) into the threaded holes in the coupling (117) until the rotor assembly is released from the coupling.

2.8.3.11 Using a crane, lift and guide the rotor assembly. Being careful not to

damage the rotor cover hub, place the assembly on a flat surface with the rotor cover facing upward.

2.8.3.12 Match mark the location of each of the twelve socket head capscrews

(7) which secure the rotor cover (4) to the rotor (3). 2.8.3.13 Remove the twelve socket head capscrews (7) and install the rotor

guide pins. Evenly thread three of the socket head capscrews (7) into the threaded holes in the rotor cover until the rotor cover is released from the toro. Replace the three capscrews with three eyebolts.

2.8.3.14 Holding the pick-up tube (1) centered in the rotor cover (4), lift the rotor

cover. 2.8.3.15 Guide the pick-up tube out of the rotor cover. Place the rotor cover on

a flat surface with the seal mating ring visible. Remove the rotor guide pins.

2.8.3.16 Grasping the outside diameter of the seal mating ring (78), pull to

remove from the rotor cover (4). If unable to remove by hand, install the seal mating ring puller and evenly thread the two capscrews against the rotor cover until the seal mating ring is free of the rotor cover.

2.8.3.17 Remove the seal mating ring o-ring (69) and rotor o-ring (6).

2.8.4 Assembly

After the parts have been cleaned and inspected, the following procedure of assembly can be done with the motor mounted vertically or horizontally as during disassembly. 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 A Drawing. 2.8.4.1 Lubricate and install the rotor o-ring (6) into the groove on the rotor

(3) lip. Install the three rotor guide pines into the rotor. 2.8.4.2 Lubricate and install the rotor drain plugs (8) in the rotor cover (4).

Torque to 13-ft. lbs. (18 N-M).

RD11 2x2 18

2.8.4.3 If required, the manifold, rotor and rotor cover can be hydrostatic

pressure tested at this stage. The pump cannot be hydrostatic pressure tested as a complete assembly. Refer to section 3.0 for hydrostatic pressure testing

2.8.4.4 Being extremely careful not to damage the seal mating ring

surface, slide the pick-up tube (1) with the protective shield through the opening in the rotor cover (4).

2.8.4.5 Holding the pick-up tube centered, align the rotor and rotor cover

match marks.

2.8.4.6 Guide the rotor cover (4) over the rotor guide pins and against the rotor (3).

2.8.4.7 Match the twelve socket head capscrews (7) with their correct

positions in the rotor cover (4).

2.8.4.8 Seat the rotor cover (4) by evenly threading the socket head capscrews (7). Replace the rotor guide pins with capscrews and torque all to 40 ft. lbs. (55 N-M).

2.8.4.9 Thread the eyebolts into evenly spaced holes in the rotor cover (4).

Adjust the eyebolt nuts until flush against the rotor cover.

2.8.4.10 Using a sling, lift the rotor assembly, being careful not to damage the rotor cover hub, place the assembly over the coupling (117) on the motor.

2.8.4.11 Evenly thread the four hex flange bolts (135) through the coupling

(117) flange and into the rotor. Torque to 35 ft-lbs. (48 N-M).

2.8.4.12 Check that the rotor has been properly assembled to the shaft coupling. Do this by measuring the radial and axial runout at the seal mating ring location of the rotorcover. The radial must be .003” TIR max and the axial must be .001” TIR max. If not, repeat the previous step until these measurements are obtained.

2.8.4.13 Place the case (31) on the backplate (13) with the 5/8” drain hole at

the bottom of the motor.

2.8.4.14 Evenly thread ten hex head capscrews (63) through the backplate (130) and into the case (31) and torque to 55 ft-lbs. (75 N-M).

2.8.4.15 Insure that the shims (38) are in place and flat against the back of

the seal mating ring (78). NOTE: For proper seal location, refer to section 5.0 for shimming.

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2.8.4.16 Lubricate and install the seal mating ring o-ring (69) in the rotor

cover (4). Lubricate the seal mating ring cavity in the rotor cover with light oil.

2.8.4.17 Slide the seal mating ring (78) over the pick-up tube (1). 2.8.4.18 Align the hole in seal mating ring with the drive pin (92) in the rotor

cover (4). Slide the seal mating ring into place until flush against the rotor cover and shims. NOTE: For proper seal location, refer to section 5.0 for shimming.

2.8.4.19 Place the seal spacer (93A) or the flush ring (93B) in the manifold

cavity. Lubricate and install the pick-up tube o-ring (49) and seal o-ring (44) in the manifold (36). Lubricate the seal cavity in the manifold with light oil.

2.8.4.20 Using the seal installation tool, insert the seal (75) into the manifold

(36) cavity being careful not to damage the seal face. Install the retaining ring (91) into the manifold groove.

2.8.4.21 Install the manifold guide pins into the case (31) holes. Clean the seal

(75) face and the seal mating ring (78). Install Manifold puller into the manifold (36).

2.8.4.22 Being extremely careful not to damage the seal or seal mating ring,

install manifold (36). Slide pick-up tube guide through manifold. Align manifold on manifold guide pins and slide into place on each case while holding pick-up tube guide centered.

2.8.4.23 Remove the manifold guide pins. Seat the manifold (36) to the case

(31) by evenly threading the ten hex head capscrews (63). Torque the capscrews to 55 ft. lbs. (75 N-M).

2.8.4.24 Remove the manifold puller. Using the pick-up tube guide, align the

manifold (36) keyway and the pick-up tube (1) keyway. Pull the pick-up tube past the o-ring (49) and against the manifold shoulder. Rotating the motor by hand may make it easier to pull up the pick-up tube.

2.8.4.25 Remove the pick-up tube guide. Install the pick-up tube key (82) into

the keyways. Using the lock nut took, thread lock nut (81) into pick-up tube. Torque lock nut to 217 ft. lbs. (294 N-M). (Remember left-hand thread.)

2.8.4.26 The pump may now be put into operation.

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3. HYDROSTATIC PRESSURE TESTING

Hydrostatic pressure testing can be done on the rotor and rotor cover as an assembly. The manifold must be tested separately.

3.1 Manifold

3.1.1 Plug inlet and outlet and seal cavity. 3.1.2 Fill completely with water. Pressurize to 300 psig (20.7 bar) and hold for 10 minutes.

3.2 Rotor and Rotor Cover

3.2.1 Assemble rotor cover to rotor per Section 2.8.4.1, 2.8.4.2, and 2.8.4.6 through

2.8.6.8. 3.2.2 Fill completely with water and plug rotor cover opening. Pressurize to 300 psig (20.7

bar) and hold for 10 minutes. 3.2.3 Drain. 3.2.4 Complete assembly per Section 2.8.4.

4 ROTOR ASSEMBLY BALANCING

Dynamic balancing of the pump's rotating assembly is necessary to eliminate excessive out-of-balance conditions which can cause vibration damage to the pump. Although each pump is dynamic balanced at the factory prior to shipment, factors, such as a change in the fluid specific gravity or extensive repairs on the pump may require the rebalancing of the rotating assembly. The following instructions are applicable to an assembled pump and motor with only the rotor, rotor cover and backplate installed. 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 A Drawing. CAUTION: Sufficient guarding should be used when balancing the rotating assembly. 4.1 Secure the motor/rotor assembly in a vertical position, with the rotorcover facing up. 4.2 Completely fill the rotor assembly with the specific gravity fluid required. The standard fluid is

water.

4.2.1 When the fluid to be pumped has a specific gravity of less than .7 or greater than 1.3, a special balance is required. A special fluid will be used for balancing that will match the fluid that will be pumped.

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4.3 Manually rotate the rotor assembly to remove air bubbles from the fluid. When all of the air bubbles have been removed, plug the opening in the rotor cover.

4.4 Secure the motor/rotor assembly in a horizontal position on a solid foundation. 4.5 Using the motor as the driver, balance the motor/rotor assembly at the following speeds:

4.5.1 15 HP, 254TC Frame, 4000 RPM 4.5.2 20 HP, 256TC Frame, 4000 RPM 4.5.3 25 HP, 284TSC Frame, 4000 RPM 4.5.4 30 HP, 286TSC Frame, 4000 RPM 4.5.5 40 HP, 324TSC Frame, 4000 RPM 4.5.6 50 HP, 326TSC Frame, 4000 RPM 4.5.7 60 HP 364TSC Frame, 3550 RPM 4.5.8 75 HP, 365TSC Frame, 3550 RPM

4.6 Single plane balance using the rotorcover balance plane as shown on Figure 4.0. The rotor

balance plan can also be used if require d for additional weight removal.

4.7 Follow the balancing procedure provided with the instrumentation being used to balance the motor/rotor assembly.

4.8 ACCEPTANCE CRITERIA (FIELD BALANCING)

4.8.1 For operating speeds above 4000 RPM:

4.8.1.1 The motor/rotor assemblies must be balanced to a maximum vibration level of .025 in/sec peak and .050 in/sec overall in any direction.

4.8.2 For operating speeds below 4000 RPM:

4.8.2.1 The motor/rotor assemblies must be balanced to a maximum vibration level of .05 in/sec peak and .100 in/sec overall in any direction.

4.9 During the balancing operating vibration readings are taken on the motor housing at the bearing

locations front and rear in both the horizontal and vertical direction and on the pump case in the axial direction.

4.10 Drain the fluid from the rotor assembly and remove the rotor cover per Section 2.8.3.12.

Complete the pump assembly.

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Figure 4.0

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5 SHIMMING

Variation in components can affect the number of shims necessary to correctly compress the mechanical seal. Referring to figure 4.0, the distance between the seal mating ring face and the case flange face is indicated by "C". In a properly shimmed pump, the distance should measure between 0.864" (21.95 mm) and 0.900" (22.86 mm). The following instructions are to determine the required number of shims. 5.1 For proper bearing and seal location, dimension "C" (as shown in Figure 4.0) 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 "C."

5.2 Referring to the shim chart below, find the line in which the measured value "C" falls. Follow the

line across and identify the number of shims required. (The shim chart is based on shims .010" thick, actual thickness may vary.)

5.3 Install the required number of shims, under the seal mating ring (as shown in Figure 4.0).

5.4 Recheck by measuring the distance "C" and checking the shim chart to insure that no additional

shims are required.

5.5 Complete assembly per Section 2.8.4.6.17 – 2.8.4.24

SHIMMING CHART SHIMMING CHART

Measured Reading "C" Number of Shims Required

Measured Reading "C" Number of Shims

Required

Inches Millimeters Inches Millimeters

.864 - .900 21.95 - 22.86 0 .814 - .823 20.68 - 20.92 5

.854 - .863 21.69 - 21.94 1 .804 - .813 20.42 - 20.67 6

.844 - .853 21.44 - 21.68 2 .794 - .803 20.17 - 20.41 7

.834 - .843 21.18 - 21.43 3 .784 - .793 19.91 - 20.16 8

.824 - .833 20.93 - 21.17 4

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6 PARTS

6.1 SPARE PARTS LIST

The following is the recommended minimum spare parts. Refer to Figures 2.4 and 2.5.

Item No.

Description

Part No.

1 Seal Kit Carbon vs. T/C (standard) Seal Kit T/C vs. T/C

0665207-CT 0665207-TT

8 Drain Plug, Rotor Cover Steel/Nitrile Stainless Steel/Nitrile

060068656 060068677

6.2 MAINTENANCE SUPPLIES

Item No.

Description

Part No.

1 Anti-Seize - Molybdenum Disulfide (1 lb.) 0661261

6.3 ACCESSORIES

Item No.

Description

Part No.

1 Valve and Gauge Package - 2" Steel w/ 3/32" Orifice 0683831

2 Valve ad Gauge Package - 2" Steel w/ 1/8" Orifice 0683831-125

3 Valve and Gauge Package - 2" Steel w/ 5/32" Orifice 0682641

4 Orifice 3/32" 0682444

5 Orifice 1/8" 0682445

6 Orifice 5/32" 0682446

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6.4 ORDERING PARTS

6.4.1 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 possible since circumstances beyond our control may reduce existing stock.

6.4.2 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.

6.4.3 Assistance - Should you need any assistance, please contact the factory or nearest regional office listed on the back cover.

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7 MAINTENANCE RECORD

DATE

SERIAL NO.

MAINTENANCE RECORD BY:

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8 APPENDIX A

When using the swivel hoist, use in place of this lifting eye.

Specification in this manual are subject to change without prior notification. Manual # RJ-DA-7 (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