disassembly/assembly manual rga iii 2x2 / rgb iii 2x2the roto-jet pump is the simplest and most...

Disassembly/Assembly Manual

RGA III 2x2 / RGB III 2x2

RJ-DA-5 11/19

ROTO-JET PUMP

DISASSEMBLY/ASSEMBLY


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 DISASSEMBLY/ASSEMBLY STANDS ............................................5

2.3.1 RG III 2x2 Dimensional Drawing ...........................................6

2.4. RG III 2x2 Section Drawing ..............................................................7

2.4.1 RG III 2x2 Section Drawing ...................................................8

2.5 RG III 2x2 ROTOR ASSEMBLY SECTION DRAWING ...................9

2.5.1 Parts List - RG Rotor Assembly .......................................... 10

2.6. Parts List - Single Seal - 2x2 Pump ............................................... 11

2.7. SEAL SHIMMING .......................................................................... 12

2.8. PREPARATION FOR DISASSEMBLY .......................................... 13

2.9. CAUTIONS .................................................................................... 13

3. DISASSEMBLY ........................................................................................ 14

3.1. SEAL REMOVAL ........................................................................... 14

3.2. ROTOR ASSEMBLY REMOVAL AND DISASSEMBLY ................ 15

3.3. ROTOR COVER AND PICK-UP TUBE REMOVAL ....................... 16

ROTO-JET PUMP



Table of Contents Continued

ii

3.4. BEARING REMOVAL .................................................................... 17

3.5. PEDESTAL BUSHING/SLEEVE REMOVAL ................................. 17

4. ASSEMBLY .............................................................................................. 18

4.1. BEARING INSTALLATION ............................................................ 18

4.2. PEDESTAL BUSHING/SLEEVE INSTALLATION ......................... 19

4.3. ROTOR COVER AND PICK-UP TUBE INSTALLATION ............... 19

4.4. ROTOR ASSEMBLY INSTALLATION ........................................... 20

4.5. SEAL INSTALLATION ................................................................... 20

5. COMPONENTS KITS ............................................................................... 23

6. ROTATING COMPONENT REPLACEMENT ........................................... 24

6.1. ROTOR REMOVAL ....................................................................... 24

6.2. ROTOR INSTALLATION ............................................................... 24

6.3. BEARING INSTALLATION ............................................................ 24

7. DRIVE BEARING CONVERSION ............................................................ 24

8. HYDROSTATIC PRESSURE TEST ......................................................... 25

9. ROTOR ASSEMBLY BALANCING ........................................................... 26

ROTO-JET PUMP



Table of Contents Continued

iii

10. PARTS ..................................................................................................... 27

10.1. MINIMUM RECOMMENDED SPARE PARTS LIST ...................... 27

10.2. PARTS LIST - AUXILIARY EQUIPMENT ...................................... 27

10.3. ORDERING PARTS....................................................................... 27

11. MAINTENANCE RECORD ....................................................................... 29

RG 2x2 1

ROTO-JET PUMP



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.

RG 2x2 2

1.3. PUMP IDENTIFICATION

Roto-Jet pumps are designated by a series of letters and numbers, such as RGB-S484. The first group, RGB, is an indication of the basic mechanical configuration and the second group, S484, 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 shaft is facing downward and the manifold is facing upward. Roto-Jet pumps offers assembly stands for mounting the unit during disassembly and assembly.

CAUTION READ THESE INSTRUCTIONS CAREFULLY BEFORE BEGINNING WORK ON THIS ROTO-JET PUMP. OBSERVE ALL INSTRUCTIONS PARTICULARLY SAFETY RELATED INSTRUCTIONS OR CAUTIONS AND USE SAFE SHOP PRACTICES.

RG 2x2 3

2.2. RECOMMENDED TOOLS

Description Quantity Part Numbers

Special Tool Kit (includes items under special tools) 1 06P661210-001

Complete Tool Kit (includes special and purchased tools) 1 06P661210-002

SPECIAL TOOLS

Alignment Tool-Pick-Up Tube (5/16” – 24) 1 060582064

Alignment Tool-Endbell 3 060580573

Center Guide-Pick-Up Tube 1 060580574

Hand Tool, Seal Installation 1 060580624

Tool Assembly-Seal Mating Ring 1 060580632

Tee, Handle Pick-Up-Tube-5/16”-24 UNF 1 060580633

Measuring Bar (For Shimming) 1 060580635

Lifting Ring, 2x2 Manifold 1 060580638

Forcing Screw, Rotor Cover – All Thd. Gr. 5 3 060580643

Pin, Guide-Endplate 1 060581220

Pin, Alignment-Rotor Cover 2 060581222

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

Puller – Smr. RG 1 0661977

Socket – 1/4” Hex Bit x 1/2” Lg., 3/8” Drive 1 060582391

PURCHASED TOOLS

Eyebolt – 1/2” – 13 x 1-1/2” Lg. Shank 3 060055411

Eyebolt – 5/8” – 11 x 4-1/2” Lg. Shank 3 060055413

Bearing Separator-Spread 1/2” – 8 5/8” 1 060095022

Puller – 17.5 Ton, 9-1/2” 1 060095023

Torque Wrench – 30-150 Ft. Lbs., 1/2” Drive 1 060095026

Torque Wrench – 5 – 80 Ft. Lbs., 1/2” Drive 1 060095027

Adapter – 3/8” Sq. Male x 1/2” Sq. Female 1 060095033

Socket – 5/32” Hex Bit, 3/8” Drive 1 060095035



RG 2x2 4

2.2 RECOMMENDED TOOLS, continued.

PURCHASED TOOLS, continued.

Description Quantity Part Numbers



Protector, Shaft Puller 1 060095037

Heat Gun – 750° Max (120V/60Hz) 1 060095046

Tempilstick – 150° F 1 060095047

Tempilstick – 175° F 1 060095048

Tempilstick – 200° 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

Connector – Leg. 5/8” – 18 to 3/4” – 16 2 060095024

Legs, Puller – 16-1/2” 1 Pr. 060095025

Legs, Puller – 22-1/2” 1 Pr. 060095056

ACCESSORIES*

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

Rotor Assembly Stand 1 0665443-01

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 and must be ordered separately.

RG 2x2 5

2.3. 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.

RG 2x2 6

RG III 2x2 Dimensional Drawing

RG 2x2 7

2.4. RG III 2x2 Section Drawing

Item Torque Ft. lbs.

Torque N.M.

117F 35 47

117G 104 141

58 54 73

45 175 237

32 185 250

64 26 35

63 104 141

7, 83 100 135

Figure 6. Torque Chart

RG 2x2 8

2.4.1. Parts List - RG III 2x2 Pump

Item No.

Qty

Description

Part No.

Item No.

Qty.

Description

Part No.

1 1 Pick-Up Tube: (1) 43 1 Driveshaft Key 060076024

S-266 17-4 PH 0656030 38 As req'd Bearing Shim 0650406

S-375 17-4 PH 0656031 58 4 Capscrew Hex Head 060088354

S-484 17-4 PH 0655625 26 1 Endbell 0662568-1

S-600 17-4 PH 0655626 36 1 Manifold 0661289

D-484 17-4 PH 0658202 42 2 Pipe Plug 060067738

D-600 17-4 PH 0655627 45 4 Hex Nut 060081111

117 Pedestal Assembly Consisting of:

0661147 32 4 Stud Bolt 0655592

117A 1 Bearing Pedestal Grease Lub.

0656683 64 8 Capscrew, Socket Head 0658775

117B 1 Pedestal Bushing 0656684 63 9 Capscrew, Socket Head 0661091

117C 1 Bearing Sleeve 0654726 73 1 Warning Plate - Direct Drive 0665538

117D 1 Bearing Cap 0661144 73 1 Warning Plate - Belt Drive 0665539

117E 1 Rotor Case 0653206 104 1 Grease Instruction Plate 0665535

117F 4 Capscrew Hex Head 060088815 37 1 Serial Number Plate 0660681

117G 8 Capscrew Hex Head 060088365 105 1 Instruction Plate 0665535

117H 2 Grease Fitting 060068705 65 16 Stud - Drive 060093116

117I 1 Pipe Plug 060067725 39 1 Eyebolt 0656866

1 Standard Seal Kit 2x2 Pump (See Section 2.6 for parts list.)

06P660622-CT 106 1 Decal (Roto-Jet) 0662029

Note: (1) Standard Units are 17-4 PH. Contact Factory representative for optional metallurgy.

RG 2x2 9

2.5. RG III 2x2 ROTOR ASSEMBLY SECTION DRAWING

RG 2x2 10

2.5.1. Parts List - RG III 2x2 Rotor Assembly

Item No.

Qty.

Description

Part No.

0661241-002 Ductile Iron RG 2x2 Balanced

0661150-020 Ductile Iron

RGA 2x2 Stacked and

Balanced

0661150-021

Ductile Iron RGB 2x2 Stacked and

Balanced (1)(2)5 1 Driveshaft 0661833 X X X

46 1 Self-locking Nut 060081346 X X

28 1 Spacer 0661143 X X

12 1 Thrust Bearing 060052138 X X

13A 1 Angular Bearing RG-A 060052138 X

13B 1 Roller Bearing RG-B 060052243 X

23 1 Thrust Bearing Spacer Set 0659489 X X

107 1 Grease Retainer 0655153 X X

108 1 Grease Retainer Spring 0655141 X X

109 1 Grease Retainer 0655151 X X

47 1 Self-locking Nut 060081347 X X

110 1 Locknut Spacer 0654752 X X

11 1 Radial Bearing 060052139 X X

111 1 Hardened Shim 0660068 X X

66 1 Wave Spring Washer 060098225 X X

15 1 Endplate 0653257 X X

7, 83 22 Capscrew 060088578 X X X (2)3 1 Rotor - Ductile Iron 0656217 X X X

6 1 O-Ring, Rotor 060083904 X X X (2)4 1 Rotor Cover 2x2 - Ductile

Iron 0661852 X X X

84 1 Excluder 060079425 X X

(1) For pumps with serial numbers prior to 86-7121, a driveshaft kit (part number 0654461)

must be used. (2) Items 3, 4 and 5. These parts, if purchased separately, must be balanced as an entire

assembly.

RG 2x2 11

2.6. Parts List - Single Seal - 2x2 Pump

Figure 4 - Single Seal - 2x2 Pump

Item No.

Qty.

Description

Part Numbers

1 1

Seal Kit - Pusher - Carbon (Standard) v.s. Tungsten Carbide Seal Kit - Pusher - Tungsten Carbide v.s. Tungsten Carbide

06P660622-CT

06P660622-TT

Consisting Of:

75

1

Seal - Pusher - Carbon Seal - Pusher - Tungsten Carbide

0660472JC

060754067

44

78

69

91

92

49

1 1 1 1 1 1

O-Ring Seal Mating Ring - Tungsten Carbide O-Ring - Mating Ring Retaining Ring - Seal Dowel Pin - Seal Mating Ring O-Ring - Pick up Tube

060083779

0652046-002

060083625

060099130

060084107

060083684

RG 2x2 12

2.7. SEAL SHIMMING

Figure 5 - Shimming Diagram RG 2x2 Pump

Shimming Chart Number of Shims

Required 0 or Required

Setting 1

2

3

4

5

6

7

8

B

inches

1.920 ---

1.906

1.905 --- 1.891

1.890 --- 1.876

1.875 --- 1.861

1.860 --- 1.846

1.845 --- 1.831

1.830 --- 1.816

1.815 --- 1.801

1.800 --- 1.786

mm

48.77 ---

48.41

48.39 --- 48.03

48.01 --- 47.65

47.63 --- 47.27

47.24 --- 46.89

46.86 --- 46.51

46.48 --- 46.13

46.10 --- 45.75

45.72 --- 45.36

RG 2x2 13

2.8. PREPARATION FOR DISASSEMBLY

WARNING PLEASE STUDY THESE INSTRUCTIONS CAREFULLY BEFORE PERFORMING PUMP MAINTENANCE. ADHERENCE TO THESE INSTRUCTIONS IS NECESSARY FOR SATISFACTORY REPAIR OR YOUR ROTO-JET PUMP. MAINTENANCE PERSONNEL MUST READ AND UNDERSTAND THE ASSEMBLY AND DISASSEMBLY SECTION.

WARNING WHEN PERFORMING EQUIPMENT MAINTENANCE OR IF THE PUMP IS TO REMAIN OUT OF SERVICE FOR A PERIOD OF TIME, THE EQUIPMENT ELECTRICAL SERVICE MUST BE LOCKED OUT WITH AN APPROVED LOCKOUT AND KEY. FAILURE TO LOCKOUT EQUIPMENT MAY RESULT IN INJURY.

(1) Lock out and tag the driver. (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.

2.9. CAUTIONS

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

1. Replace any o-rings that are exposed during the pump disassembly process as

they lose their seal integrity and may leak.

2. When removing or replacing the pick-up tube, always replace the pick-up tube capscrews to eliminate any over stressed bolts.

3. Be sure all parts are free of dirt, stray metal chips or any foreign matter and have

been thoroughly cleaned. 4. All torque values given assume lubrication with molybdenum disulfide on threads

and underside of capscrew heads. Refer to figure 2.4 for torque values. 5. All three bearings should be replaced as a set. 6. 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.

RG 2x2 14

7. Replacement of the rotor, rotor cover or driveshaft will require balancing or

rotating assembly and shimming of pump. See section 6.0. 8. 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 4 Drawing.

WARNING THE EYE-BOLT HOLE LOCATED ON THE TOP OF THE PUMP HOUSING IS INTENDED FOR LIFTING THE PUMP ONLY, AND NOT THE COMPLETE PUMP AND BASE PACKAGE.

WARNING EQUIPMENT LIFTING DEVICES SUCH AS CHAIN, LIFTING EYES, HOOKS, ETC. MUST BE APPROVED BY LOCAL, STATE OR FEDERAL SAFETY CODES. HOISTS AND CRANES MUST BE ADEQUATELY SIZED TO LIFT RATED LOADS. FAILURE TO USE APPROVED LIFTING DEVICES MAY RESULT IN INJURY. WHEN LIFTING THE PUMP, IT IS IMPORTANT TO MAKE SURE THAT THE CHAIN AND CABLES ARE FASTENED RELIABLY TO THEIR RETAINING HOOKS.

3. 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 4 Drawing. To disassemble the Roto-Jet pump, refer to Section 2.4 and 2.5. 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 facing downward and the endbell is facing upward.

3.1. SEAL REMOVAL

RG 2x2 15

3.1.1. Remove the eight socket head capscrews (64) in the discharge port of the manifold

(36) which secure the pick-up tube (1) to the manifold.

3.1.2. Insert the pick-up tube center guide all the way into the pick-up tube (1) and push or tap lightly until the pick-up tube moves free of the pick-up tube o-ring (49) and manifold (36).

3.1.3. Remove the four hex nuts (45) which secure the manifold (36) to the endbell (26) lift

and remove the manifold (36) from the endbell (26). Place the manifold on a flat surface with the manifold ports facing down.

3.1.4. In this position, carefully remove the seal retaining ring (91) from the manifold (36). To

remove the mechanical seal (75) from the manifold, use the seal puller included in the tool kit, or gently tap the back side of the mechanical seal with a brass rod inserted through the discharge port of the manifold (36) until the mechanical seal is free to be removed by hand.

3.1.5. Using an O-Ring pick, remove the mechanical seal o-ring (44) and pick-up tube o-ring

(49) from the manifold (36).

3.1.6. 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 face.

3.1.7. Using a hand tool (P/N 0661977), remove the seal mating ring (78) from the rotor

cover (4) until the seal mating ring is free to be removed by hand.

NOTE: If only the mechanical seal (75) and seal mating ring (78) replacement is necessary, no further disassembly is required. See section 4.5 for reassembly of seal. See section 3.3 for rotor cover and pick-up tube removal.

3.2. ROTOR ASSEMBLY REMOVAL AND 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 4 Drawing.

Recommended the unit is mounted vertically with the shaft downward and the rotor facing upward when rotor assembly is removed.

3.2.1. Remove two of the nine 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 remainder of socket head capscrews (63). Thread eyebolts (P/N 06055404) into three evenly spaced, tapped jackscrew holes and using a sling, lift and remove the endbell (26) from the rotor case (117E).

RG 2x2 16

3.2.2. Remove the driveshaft key (43).

3.2.3. Remove shaft slinger (84).

3.2.4. Remove the four hex head capscrews (58) which secure the endplate (15) to the

pedestal (117A).

3.2.5. Thread the three 1/2" eyebolts (P/N 060055411) into three evenly spaced 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).

3.3. ROTOR COVER AND PICK-UP TUBE REMOVAL (Reference figure 2.5)

3.3.1. Remove two of the nine 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 remainder of socket head capscrews (63). Thread eyebolts (P/N 060055404) into three evenly spaced, tapped jackscrew holes and remove the endbell (26) from the rotor case (117E).

Special Note: See Appendix 2 for endbell design change.

3.3.2. Identify position of each rotor cover capscrew (7) to their location.

NOTE: They MUST be re-assembled in the same location.

3.3.3. Remove two of the sixteen rotor cover socket head capscrews (7) and install the two

(2) rotor cover guide pins (P/N 0600581222). Remove the remaining sixteen socket capscrews (7). Thread three jackscrews evenly into the three tapped jackscrew holes in the rotor cover until it is released from the rotor.

Special Note: See Appendix 3 for labyrinth bushing design change.

3.3.4. Replace the three jackscrews with three 1/2" eyebolts (P/N 060055411) and remove

the rotor cover (4). Remove the pick up tube (1) and the rotor o-ring (6). Place rotor cover back on rotor for bearing removal. See Section 4.3 for rotor cover & pick-up tube installation.

3.3.5. Remove rotor assembly from the stand. Place the rotor assembly on a flat surface.

Remove assembly eyebolts from the rotor and thread in three 1/2" jackscrews to lock and prevent damage. Install a 5/8" eyebolt into the end of the shaft with the rotor facing downward and shaft facing up, then place the rotor assembly on rotor assembly stand (Reference figure 2.3).

CAUTION: Be sure to lock the rotor assembly on the stand and care should be taken not to damage the o-ring lip on the rotor (3).

RG 2x2 17

3.4. BEARING REMOVAL

3.4.1. Remove seal excluder.

3.4.2. Remove self locking nut (46) using a bearing locknut torque wrench adapter (P/N

0600580571), and discard locknut.

3.4.3. Remove the spacer (28).

3.4.4. Slide the grease retainer (107) from the thrust bearing (12) and install the bearing separator (P/N 060095022) in an upside down position under the thrust bearing. Make sure the separator is installed so it will pull on the inner bearing race. Remove the radial bearing (13A), or thrust bearing (13B) spacer set (23) and the thrust bearing (12) all at once.

3.4.5. Remove the grease retainer (107), grease retainer spring (108), and rotor bearing

grease retainer (109).

3.4.6. Apply bearing locknut torque wrench adapter (P/N 060050570) and remove the self locking nut (47) and locknut spacer (110). Discard locknut.

3.4.7. Again, install the bearing puller, remove the rotor bearing (11), by hand remove

bearing shim (111) washer (66) and endplate (15).

3.4.8. Remove the six socket head capscrews (83) which secure the rotor (3) to the driveshaft (5) only if rotor or drive shaft needs replacement.

Special Note: Serial number prior to 86-7121, see Appendix 1.

3.4.9. 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.

3.5. PEDESTAL BUSHING/SLEEVE REMOVAL

3.5.1. Remove the four hex head capscrews (117F) which secure the bearing cap (117D) to

the pedestal (117A) and remove the bearing cap.

3.5.2. Inspect bearing sleeve (117C) and pedestal bushing (117B) for wear, scratches, or gaul marks. If present, replace before reassembly.

3.5.3. Removal: Pull or tap bearing sleeve and/or pedestal bushings from pedestal bore

using puller or brass rod.

RG 2x2 18

4. ASSEMBLY

4.1. BEARING INSTALLATION

Note: Balancing - If any rotating components replaced, i.e., shaft, rotor or rotor cover, the rotor assembly must be balanced in accordance with section 7.2).

4.1.1. Heat the driveshaft bore in the rotor (3) to 140° - 160° F. 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 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 2.5).

Fill the reservoir to 25% of its capacity with an approved grease. Be careful not to over lubricate! Install wave spring (66) and then 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 2.5) 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. Install the locknut spacer (110) and self-locking nut (47). Torque to 250 ft. lbs.

4.1.6. Place rotor bearing grease retainer (109), grease retainer spring (108) and grease retainer (107) onto the shaft as shown in assembly drawing (Figure 2.5).

4.1.7. Heat the thrust bearing (12) to 150°-175° degrees 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 shaft. Hold bearing against the shoulder of the shaft until the interference fit engages.

4.1.8. Hand pack the bearing with grease 50% full, working grease into the cage and


4.1.9. Now slip the grease retainer (107) over the outer race of the thrust bearing (12) so the retainer shoulders fit in place.

4.1.10. Place the thrust bearing spacer set (23) around the shaft (5) and against the thrust

bearing (12).

4.1.11. For Model RG-A: 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.

RG 2x2 19

4.1.12. For Model RG-B: 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.



4.1.14. Install spacer (28) on shaft.

4.1.15. Place self-locking nut (46) on the shaft (11) and torque to 175 ft. lbs.

4.2. PEDESTAL BUSHING/SLEEVE INSTALLATION

4.2.1. Press the bearing sleeve (117C) into the bore of the pedestal. Locate the face of the bearing sleeve .582 below the face of the pedestal. The face of the sleeve must be parallel to the face of the pedestal within .001 inches.

4.2.2. Press the pedestal bushing (117B) into the pedestal (117A) and seat the bushing

against the pedestal shoulder.

4.2.3. Fasten the bearing cap (117D) to the pedestal (117A) with the four hex head capscrews (117F). Tighten the capscrews - 35 ft. lbs.

4.3. ROTOR COVER AND PICK-UP TUBE INSTALLATION

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 4 Drawing.

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 1/2" eyebolts (P/N 060055411) into three evenly spaced holes at the periphery of the rotor cover (4). Place rotor assembly back on the rotor assembly stand with the shaft facing down. Remove the three 1/2" 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 pickup tube (1)

in the rotor. Lubricate the o-ring bore in the rotor cover (4) which engages the rotor o-ring (6).

RG 2x2 20

4.3.3. Place the rotor cover (4) using three 1/2" eyebolts (P/N 060055411) on the rotor (3)

with two alignment pins (P/N 060581222). 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 sixteen socket head capscrews (7) into their original rotor cover capscrew

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 capscrews to 100 ft. lbs.

4.4. ROTOR ASSEMBLY INSTALLATION

4.4.1. Install rotor alignment tool (P/N 0600581220) into endplate (15) as a guide for rotor

assembly.

4.4.2. Place three 1/2" eyebolts (P/N 060055411) into the holes in periphery of the rotor cover. Lift the rotor assembly by the eyebolts, and carefully slide the assembly into the pedestal. BE SURE THAT:

A) The alignment tool in the endplate (15) goes through the corresponding

hole in the pedestal (1) 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 (117E) after the rotor (3), cover (4) and shaft (5) are in place.

4.4.3. Remove the alignment tool.

4.4.4. Install the endplate to pedestal with four capscrews (58). Torque to 54 ft. lbs.

NOTE: EACH FITTING MUST BE GREASED WITH ONE (1) OZ. OF FACTORY AUTHORIZED GREASE.

4.5. SEAL INSTALLATION

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 4 Drawing.

4.5.1. Lubricate and install seal mating ring O-ring (69) in the hub of the rotor cover (4).

Align the drive-pin (92) with the hole in the mating ring and insert the seal mating ring (78) into place using the seal mating ring installation tool (P/N 060580632). The seal mating ring should move back and forth within the drive-pin hole.

* NOTE: IF YOU ARE ONLY INSTALLING A PICK-UP TUBE OR SEAL

STEPS 2-4 & 6 ARE NOT REQUIRED.

RG 2x2 21

4.5.2. For proper bearing and seal location, dimension "B" (as shown in figure 5) 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 shim chart (Figure 5) to find the box in which the measured value "B" falls. (The shimming chart is based on shims .015" thick, actual thickness may vary).

4.5.3. Now tilt the pump from its vertical position to a horizontal position. Remove the four

hex-head capscrews (117F) and bearing cap (117D). Install the correct number of shims (38). Reinstall the bearing cap and four capscrews (117F) and torque to 35 ft. lbs. Return the pump to a vertical position.

4.5.4. Again measure dimension "B" to be certain it is now correct.

4.5.5. 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 runout of the face must be within .001" (0.025 mm) T.I.R.

4.5.6. Install alignment tools (P/N 0600580573) in rotor case (117E) for endbell/rotor case

alignment. Align endbell so that the 1/2" drain hole is at the bottom. Carefully slide the endbell (26) into place. Lubricate and install the nine endbell socket head capscrews (63) and torque to 104 ft. lbs.

4.5.7. Lubricate and install pick-up tube o-ring (49) and mechanical seal o-ring (44) into the

manifold (36). Using seal installation tool (P/N 060580624), 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. Install the seal retaining ring (91).

NOTE: Before installing the manifold (36) to the endbell (26) it is very

important that the mating machine surfaces of both these parts be thoroughly cleaned.

4.5.8. Install the center guide (P/N 060580574) through the manifold discharge port and a

pick-up tube alignment tool (P/N 060582064) in one of the tapped pick-up tube capscrew holes. Make sure pick-up tube (1) and manifold (36) is in it's corresponding position. Make certain that the center guide, alignment tool, and pick-up tube (1) does not hit the mechanical seal. Slide manifold over studs. Install 4 nuts (45) on studs and torque to 175 ft. lbs.

4.5.9. Remove the center guide. Install tee handle into one of the tapped pick-up tube

capscrew holes. Lift upward, bring the pick-up tube (1) upward until it is fully shouldered against the discharge port of the manifold (36). NOTE: Always install new pickup tube capscrew (64) when installing a

pick-up tube (1).

4.5.10. Install the eight socket head capscrews (64) which secure the pick-up tube to the manifold (36). Torque evenly the eight pick-up tube capscrews (64) to 26 ft. lbs.

RG 2x2 22

4.5.11. Rotate driveshaft end 360° to make sure that the rotating assembly moves freely.

4.5.12. The pump can now be returned to service.

WARNING WHEN PUMP HAS BEEN TAKEN OUT OF SERVICE TO PERFORM MAINTENANCE OR REPAIRS, PLEASE STUDY THE OPERATING INSTRUCTIONS IN THE INSTALLATION, OPERATION AND MAINTENANCE MANUAL BEFORE INSTALLING OR OPERATING THE PUMP.

RG 2x2 23

5. COMPONENTS KITS

Assembly Number

Description

Part Number

Qty.

06P660622-CT Seal Kit, Non-Abrasive Service Mechanical Seal, Carbon Face Seal Mating Ring O-ring, Seal O-ring, Seal Mating Ring Retaining Ring, Seal O-Ring, Pick-up Tube Drive Pin, Seal Mating Ring

0660472 0652046

060083779 060083625 060099130 060083684 060084107

1 1 1 1 1 1 1

06P660622-TT Seal Kit, Abrasive Service Mechanical Seal, Tungsten Carbide Face Seal Mating Ring O-Ring, Seal O-Ring, Seal Mating Ring Retaining Ring, Seal O-Ring, Pick-up Tube Drive Pin, Seal Mating Ring

060754067 0652046

060083779 060083625 060099130 060083684 060084107

1 1 1 1 1 1 1

06P661016 Bearing Kit, Model RGA Bearing Bearing Locknut Locknut Ring and Spacer Set Wave Spring Washer Hardened Shim Slinger, Shaft

060052138 060052139 060081346 060081347 0659489

060098225 0660068

060079425

2 1 1 1 1 1 1 1

06P661016-001 Bearing Kit, Model RGB Bearing Bearing Bearing Locknut Locknut Ring and Spacer Set Wave Spring Washer Hardened Shim Slinger, Shaft

060052138 060052139 060052243 060081346 060081347 0659489

060098225 0660068

060079425

1 1 1 1 1 1 1 1 1

06P661017-003 Pick-Up Tube Replacement Kit, Two-Piece Endbell Capscrew - Socket Head, Pick-up Tube O-Ring, Pick-up Tube O-Ring, Rotor

0658775

060083684 060083904

8 1 1

0653868 Endbell Kit Endbell Manifold Capscrew - Socket Head, Pick-up Tube Hex Nut Stud Bolt Pipe Plug Decal, Endbell

0660987 0661289 0658775

060081111 0655592

060067738 0662029

1 1 8 4 4 2 1

0654461 Driveshaft Kit Driveshaft Spacer Bearing Cap, Pedestal Capscrew - Socket Head, Driveshaft Slinger, Shaft

0661833 0661143 0661144

060088578 060079425

1 1 1 6 1

RG 2x2 24

6. ROTATING COMPONENT REPLACEMENT

6.1. ROTOR REMOVAL

6.1.1. Remove the six socket head capscrews (83) which secure the rotor (3) to the driveshaft (5).

6.1.2. Mark the driveshaft (5) and the rotor (3) so that they may be reassembled with the

same relative positions for balance considerations. Thread two capscrews evenly into the two tapped jackscrew holes in the driveshaft flange until the driveshaft is released from the rotor.

6.2. ROTOR INSTALLATION

Heat the driveshaft bore in the rotor (3) to 140°-160° F. 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 capscrews (83). Do not tighten the screws until the driveshaft and the rotor have reached the same temperature, then torque to 100 ft. lbs.

6.3. BEARING INSTALLATION

Install bearing per section 4.1.

NOTE: Balancing - If rotor has been removed or any rotating components

replaced, i.e., shaft, rotor or rotor cover, the rotor assembly must be balanced in accordance with section 9.

7. DRIVE BEARING CONVERSION

7.1. RG conversion. (Reference figure 2.5.)

7.2. Preparation. Remove rotor assembly per section 3.0.

7.3. Convert from RG-B (belt drive) to RGA (direct drive).

7.3.1. Remove self-locking nut (46) using a bearing locknut wrench adapter. Discard nut.

7.3.2. Remove the spacer (28).

7.3.3. Slide the grease retainer (107) from the thrust bearing (12), and install the bearing separator under the thrust bearing 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).

RG 2x2 25

7.3.4. Heat the bearing (12) to 150°-175° F. Check the temperature with the heat stick.

Place the bearing on shaft with the wide shoulder of the inner race against the shoulder of the shaft. Hold bearing against the shoulder of the shaft until the interference fit engages.



7.3.6. Now slip the grease retainer (107) over the outer race of the thrust bearing so the retainer shoulders fit in place.

7.3.7. 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 set is a matched set, check to be sure that both parts are matched with the same set number.

7.3.8. 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.



7.3.10. Install spacer (28) on shaft (5).

7.3.11. Screw self-locking nut (46) on the shaft (5) and torque to 175 ft. lbs.

7.3.12. Complete assembly per section 4.2.

7.4. Convert from RG-A (direct drive) to RG-B (belt drive).

7.4.1. Repeat section 7.3, replace step 7.3.11 with 7.4.2.

7.4.2. 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).

8. HYDROSTATIC PRESSURE TEST

8.1. Hydrostatic pressure tests cannot be performed on assembled pumps because of possible seal damage. Hydrostatic pressure test, if desired, can be performed on the manifold and/or rotor cover.

RG 2x2 26

8.2. Manifold - Hydrostatic test suction to 1-1/2 times the maximum inlet pressure. Test outlet to 1-1/2

time the maximum discharge pressure shown on pump performance curves. Hold test for 10 minutes.

8.3. Rotor and rotor cover. Hydrostatic pressure test to 1-1/2 time the maximum inlet pressure. Hold

test for 10 minutes.

9. ROTOR ASSEMBLY BALANCING

NOTE: ALL ROTATING COMPONENTS MUST BE THOROUGHLY CLEAN BEFORE ROTOR ASSEMBLY BALANCING IS DONE.

9.1. If rotor has been removed or any rotating components, i.e., shaft, rotor or rotor cover replaced, the

rotor assembly must be dynamically balanced with Section 7.2.

9.2. 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 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 capscrews are installed in same location from which they were removed. Tighten evenly the sixteen rotor cover capscrews (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 capscrews to 100 ft. lbs.

9.3. Completely fill rotor cavity with liquid of required specific gravity. Seal off.

9.4. Position half key in shaft.

9.5. Two plane dynamic balance using surface A and B shown on figure 2.5. Trim balance to 1/2 of

the out of balance by drilling as indicated on figure 2.5. Balance to within the following limits at 970 to 1000 RPM: Caution: Sufficient guarding should be used when balancing the rotating assembly.

.15 in .oz max. per plane.

9.6. Drain rotor assembly.

9.7. Remove rotor cover (4) to prepare for next assembly step. See section 4.3.

RG 2x2 27

10. PARTS

10.1. MINIMUM RECOMMENDED SPARE PARTS LIST OF THE MODEL RG-A AND RG-B

ROTO-JET PUMPS

ITEM

RG 2 x 2

Bearing Kit RGA - Direct Drive RGB - Belt Drive

06P661016

06P661016-001

Seal Kit Non-Abrasive Service - 2-1/2" Carbon T/C Abrasive Service - 2-1/2" TC VS TC

06P660622-CT 06P660622-TT

Pick-up Tube Replacement Kit, RG 2x2 06P661017-003

10.2. PARTS LIST - AUXILIARY EQUIPMENT

BYPASS ORIFICE Description Part Number

Orifice - 3/32" 0682444

Orifice - 1/8" 0682445

Orifice - 5/32" 0682446

10.3. ORDERING PARTS

10.3.1. 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.

10.3.2. 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.

RG 2x2 28

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.

10.3.3. Assistance - Should you need any assistance, contact the factory or nearest regional

office listed on the back cover.

RG 2x2 29

11. MAINTENANCE RECORD

DATE SERIAL NO. MAINTENCE RECORD BY:

Appendix 1

RG DRIVESHAFT DESIGN MODIFICATION

Replacement kit P/N 0654461 Replacement kit P/N 0661142 consisting of the following: consisting of the following:

Item No.

Qty. Part No. Description Item No.

Qty. Part No.

Description

1 1 0661833 Shaft 1 1 0661833 Shaft

2 1 060079425 Excluder Seal 5 6 0661866 Capscrews

3 1 0661143 Spacer

4 1 0661144 Bearing Cap

5 6 0661866 Capscrews

1) Shaft A was designed without a spacer, which makes it shorter than shafts B & C. Shaft A and spacer on shaft B are obsolete.

2) When shaft A is replaced, P/N 0654461 is required for conversion. 3) When shaft B is replaced, items 2-4 are required for conversion. 4) If the V-seal needs to be replaced and it is not available from the factory use items 2-4 for

replacement parts. Model 1 & 2 Bearing Cap New Style Bearing Cap

Model 1 Model 2 Current

5) P/N 0661866, 2" long capscrew is being used because there are still old style rotors in the field

which have _" deep counter bore holes. The threads on these do not start at the top of the hole, therefore, P/N 0600088578, 1_" long (standard size for present assembly) will not work.

Appendix 2

RG ENDBELL REPLACEMENT

Background Information: The endbell configuration on single seal, ductile iron RG model units have been modified from a one piece design in RG I and RG II to a two piece design in RG III. The following information applied to field replacement of RG I or RG II endbells as well as conversions to new style endbell configuration. When endbell (P/N 0653868) is being replaced, an endbell kit (P/N 0653868) will be supplied as follows:

Item Qty. Part No. Description NOTE: All subsequent orders for pick-up tube

capscrews (P/N 0658775) should be specified.

26 1 0660987 Endbell

36 1 0661289 Manifold 2x2 D.I.

42 2 060067738 Plug Pipe

45 4 066081111 Nut

32 4 0655592 Stud

64 8 0658775 Capscrew Pick-up Tube

106 1 0662029 Decal Roto-Jet Endbell

Diagram: RG III Endbell Configuration

Appendix 3

LABYRINTH BUSHING KIT

The current RG 2x2, design Roto-Jet is only available with a single seal design in Ductile iron construction. The rotor cover of the RG 2x2 is a solid cover and does not incorporate a labyrinth bushing. The following information is provided for labyrinth bushed rotor covers still in service.

Kit Includes These Parts

Labyrinth Bushing Kit Bushing (1) Capscrew (2)

Description Kit Part No.

Part No.

Quantity

Part No.

Quantity

RG 2x2 Ductile Iron Single Seal RG 3x2 Steel RG 3x2 Stainless Steel RO Steel RO Stainless Steel

0658752 0658752-001 0658442 0658752-001 0658442

0661592 0661832 0661592-001 0661832 0661592-001

1 1 1 1 1

060088654 060088925 060088925 060088925 060088925

5 5 5 5 5

Capscrew Torque Requirement - Lubrication for torque values is required; use molybdenum disulfide lubricant. Assembly: - Place Labyrinth Bushing on Rotor Cover. Install the five capscrews and tighten down evenly to draw the labyrinth bushing down on the rotor cover. It is important that the labyrinth does not cock in the rotor cover. Torque capscrews to 26 ft. lbs. Alternate Method - Heat the Rotor Cover to 150° F - 175°F (65° - 79°C) and place the Labyrinth Bushing in the rotor cover making sure that all holes are aligned. Install the five capscrews. Do not tighten capscrews until the labyrinth bushing and the rotor cover have reached the same temperature, then torque to 26 ft. lbs.

Appendix 4

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-5 (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

disassembly/assembly manual rga iii 2x2 / rgb iii 2x2the roto-jet pump is the simplest and most...

Documents