m 103 0808 en1 · 1.6 health and safety information general first aid if potentially hazardous...

M/103/0808/EN1

Series D

Ductile Iron Positive Displacement Rotary Lobe Pumps Operating Manual

al

Represented By KGO

Operating Manual

Operating Manual

ContentsPage No

111123

4445

66789

101111121314

1515161617181818

1.0 General

1.1 Pump Limits of Application or Use1.2 Duty Conditions1.3 Noise Levels1.4 Utility Requirements1.5 Safety Precautions1.6 Health and Safety Information

2.0 Unpacking, Handling and Storage

2.1 Documents2.2 Unpacking2.3 Handling2.4 Pump Storage

3.0 Description of Pump or Pump Unit

3.1 General Pump Description3.2 Principle of Operation3.3 Pump Dimensions3.4 Pump and Pump Unit Weights3.5 Pump Displacement and Capacities

4.0 System Design and Installation

4.1 System Design Advice4.2 Pump and Base Foundations4.3 Installation4.4 Coupling Misalignment4.5 Pulley Belt Tension Adjustment4.6 Pipework

5.0 Commissioning

5.1 Recommended Lubricants5.2 Lubricating the Pump5.3 Flushed Seal Arrangements5.4 Connecting the Flush5.5 Flushing Pipework Layout5.6 Flushed Seal Housing Connections5.7 Flushing Fluid5.8 Flushing Pressure and Flow Rate

Operating Manual

Contents

6.0 Start up, Shut Down and Cleaning in Place

6.1 Start up Checklist6.2 Pump Shut Down Procedure6.3 Direction of Rotation

7.0 Maintenance and Inspection

7.1 Maintenance Schedule7.2 Recommended Spare Parts7.3 Urethane Rotors7.4 Maintenance Tools

8.0 Rotor Retention

8.1 Torque Locking Assembly - Mounting Instructions8.2 Torque Locking Assembly - Release Instructions8.3 Rotor Retention - Torque Locking Assembly

9.0 General Maintenance

9.1 Before Dismantling the Pump9.2 Removing the Rotors9.3 Removing the Rotorcase9.4 Replacing the Front Gearcase Seals9.5 Fitting and Shimming the Rotorcase9.6 Front Cover Reversal9.7 Removal of Rear Gearcase Cover and Replacement of Seals9.8 Refitting the Rotors9.9 Wearplates

10.0 Gearbox Components

Page No

192020

21212122

232324

252627282929303031

32333333333434343435

10.1 Timing Gears10.2 Timing Adjustment10.3 Timing Gear Removal10.4 Lipseal - Removal and Fitting10.5 Fitting the Timing Gears10.6 Shaft Removal10.7 Bearings General10.8 Bearings Removal10.9 Fitting Bearings to the Shaft10.10 Shaft Replacement

Operating Manual

Contents

11.0 Product Seal, Removals and Fittings

11.1 Single Mechanical Seal11.2 Single Flushed Mechanical Seal11.3 Double Mechanical Seal11.4 Packed Gland11.5 Packed Gland with Flush11.6 Cartridge Mechanical Seal

12.0 Faults, Causes and Remedies

13.0 Technical Data

13.1 Pump Information Chart13.2 Seal Specification Chart13.3 Torque Specification Chart

14.0 Exploded Drawings and Parts List

14.1 Priming Adaptor Ports14.2 D4 Pump14.1 D5 Pump14.2 D6 Pump

Page No

363738394041

42

434344

45464850

Operating Manual

1.1 Pump Limits of Application or Use

This range of pumps has been designed to offera wide span of transfer duties throughout industrywhere the use of stainless steel for pumpheadcomponents is not essential.

Pressures of up to 15 bar, speeds to750rpm andtemperatures to 200°C can be obtained on thisrange of pumps depending on pump model/size.These conditions cannot always be obtainedsimultaneously. The model type/size will beshown on the nameplate positioned on the pump.

The pump/pump unit will have been selectedfrom the pump users specific application whenknown and the pump serial number will relate tothis.

If the user has not specified the pumpingapplication or needs to change it, it is importantto confirm that the materials of construction andproduct seals are compatible with the pumpingapplication and that adequate NPSH is available

It is therefore strongly recommended that theuser contact the supplier quoting :- pump model/size, serial number and system details (e.g.product, pressure, flow rate).

1.2 Pump Duty Conditions

The pump should only be used for the duty forwhich it has been specified. The operatingpressure, speed and temperature limits havebeen selected at the time of order and MUSTNOT be exceeded for the pump. These detailsare stated on the original documentation and ifnot available may be obtained from your supplierquoting :- pump model and serial number.

1.0 General

in excess of 85dB [A]. When necessary personalprotection against noise should be taken tosafeguard the hearing of persons who are likelyto be in close proximity to the equipment.

Please contact SSP Pumps for further informationif necessary.

1.4 Utility Requirements

Electrical Supply :-

This pump may be supplied bareshaft or coupledto a drive unit for which a drive unit/electricalsupply will be required.

Note : The pump may be also driven by a dieseldrive unit.

Water Supply :-

Additional water supplies may be required if thepump is fitted with a product seal flushingarrangement. Consult your supplier for flushfluids compatible with products pumped.

1.3 Noise Levels

Under certain operating conditions pumps and /or drives and / or the systems within which theyare installed can produce sound pressure levels

1

Operating Manual

Warning Signs :

General safety instructions arepreceded by this symbol.

Electrical safety instructions arepreceded by this symbol.

Take great care when using causticagents.

1.5 Safety PrecautionsAll warnings in this manual are summarised onthis page.Pay special attention to the instructions belowso that severe personal injury or damage to thepump can be avoided.Personnel performing installation, operationand maintenance of the pump must have therelevant experience required.

Installation

Operation

Maintenance

: In certain circumstances the gearbox and pump may become very hot. Never touch the pump without wearing protective clothing

: Always observe the technical data.

: The pump must be electrically connected by authorised personnel. (See the motorinstructions supplied with the drive unit).

: Never start in the wrong direction of rotation with liquid in the pump.

: Never put your hands or fingers inside the port connections


: Never touch the pump or the pipelines when pumping hot liquids.

: Never stand on the pump or pipelines.

: Never run the pump with the suction side or the pressure side blocked.

: Always handle toxic and acidic liquids with great care.

: Never put your hands or fingers inside the port connections.

Study this manual carefully


: Always disconnect the pump from the drive unit and power supply when servicing the pump.

: The pump must never be hot when servicing it.

: The pump and pipelines must never be pressurised when servicing the pump.

: Never put your hands or fingers inside the port connections.

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Operating Manual

Material Use Major Hazard

SILICON SEALANT GEARBOX SEAL RETAINERS, REAR RELEASES VAPOUR AT ROOMCOVER, GENERAL SEALANT. TEMPERATURE.

SEALANT (RED HERMETITE) GEARBOX SEAL RETAINERS, REAR RELEASES VAPOUR AT ROOMCOVER, GENERAL SEALANT. TEMPERATURE, HIGHLY

FLAMMABLE, TREAT AS FIREHAZARD.

ANTI-SEIZE COMPOUNDS BEARINGS APPLIED FROM AEROSOL.RELEASES VAPOUR. DISPOSEOF CONTAINER AS IFPRESSURISED.

ADHESIVES (E.G. PERMABOND) BEARING NUTS, ADJUSTMENT NUTS. RELEASES VAPOUR AT ROOMTEMPERATURE.

OIL AND GREASE OIL - GENERAL LUBRICATION SKIN AND EYE IRRITANT.GREASE - PRODUCT SEALS,TIMING GEARS, GENERALLUBRICATION.

PLASTIC COMPOUNDS (PTFE, PTFE - 'O' RINGS, LIP SEALS, GLAND RELEASES FUMES WHEN POLYPROPLYENE, PVC) PACKING. POLYPROPLYENE - GLAND HEATED.

GUARDS. PVC - GLAND GUARDS.

ELASTOMERIC COMPOUNDS ALL - 'O' RINGS, LIP SEALS. NITRILE, RELEASES FUMES WHEN (EP, VITON, NITRILE, NEOPRENE POLYURETHANE - ROTORS (KNOWN HEATED.

AS RUBBER AND URETHANE).

ARAMID FIBRE GLAND PACKING. EMMITS HARMFUL DUST.RELEASES FUMES WHENHEATED.

PAINT EXTERNAL PUMP SURFACES. RELEASES DUST AND FUMESIF MACHINED. TREAT AS AFIRE HAZARD.

Potential Safety HazardsThe following section gives information onhandling, storage and disposal of parts andmaterials used in the pumps which may beconsidered hazardous to health.

Please pass this information on to your SafetyOfficer, he may need it to comply with Healthand Safety, and COSHH regulations.

Electric motors - the pump may have an electricmotor fitted, ensure that the relevant fireequipment is available.

The information contained here is brief.

1.6 Health and Safety Information General First Aid

If potentially hazardous substances areaccidentally inhaled, or skin or eyescontaminated, then the following basicprecautions should be taken

Inhalation - Remove to fresh air

Skin - Wash with soap and water

Eyes - Flush with water, seek medicalattention

In all cases, if symptoms persist, seek medicalattention.

3

Operating Manual

To avoid any problems, on receipt of your pumpalways use the following procedure:-

2.1 Documents

1. Check the delivery note against the goodsreceived.

2. If the pump has been delivered with anelectric motor check that the motorinstructions are available.

2.2 Unpacking

Care must be taken when unpacking the pump,and the following stages must be completed:-

1. Inspect the packing for any possible signsof damage in transit.

2. Carefully remove the packing away fromthe pump.

3. Inspect the pump for any visible signs ofdamage.

4. Clean away the packing from the pumpport connections.

5. Ensure that any additional equipment suchas seal flushing pipework is not damaged.

2.0 Unpacking, Handling and Storage

Pump Pedestal Mounted

2.3 HandlingDLINGRefer to the pump weights guide, prior to usingany lifting gear. Use the correct lifting slings forthe pump weight (or pump and drive ifapplicable).

The following details show how the pumpsshould be lifted.

Bareshaft Pump :- the slings should bewrapped around the ports and the drive shaft.

Pump with in-line Drive Unit:- the slingsshould be positioned around the pump rotorcaseand under the motor.

Note :- To stop the slings slipping always crossthe slings on the lifting hooks.

Bareshaft Pump

Pump with in-line Drive Unit4

Operating Manual

2.4 Pump Storage

After receipt and inspection if the pump is not tobe installed immediately the pump should berepacked and placed in suitable storage. Thefollowing points should be noted:-

1. Plastic or gasket type port covers shouldbe left in place.

2. Pumps received wrapped with corrosioninhibiting treatment material should berewrapped.

3. A clean, dry, vibration free location shouldbe selected. If stored in a moistatmosphere, further protect the pump orunit with a moisture repellent cover until itis to be installed.

4. Rotate pump/pump unit by hand, weekly,to prevent bearing and gear damage.

5. All associated ancillary equipment shouldbe treated similarly.

6. If the pump is fitted with a diesel/petrolengine it is advisable to disconnect thepump and run the engine every twomonths.

5

Operating Manual

KS

Key

& Sh

aft D

ia

4Holes'U'

ØS

T

BB

KW K

ey W

idth

F

Sha

ft D

is

J

G

HT

HB

QE

C

U

14

14

14

14

14

1414

All dimensions in mm

D

L

NPM

R

T

150

150

180

180

180

190190

S

184

184

210

210

210

220220

R

255

255

275

275

275

370370

Q

35

35

35

35

35

4040

P

150

150

180

180

180

260260

N

225

225

279

279

279

266266

M

122

138

125

145

145

163188

L

597

628

699

719

747

832857

KW

10

10

14

14

14

1414

KS

41

41

48.5

48.5

48.5

51.551.5

G

80

80

110

110

110

110110

F

38

38

45

45

45

4848

C

163338*163338*

195315*195315*195

225225

A

75

100

100

100

150

150150

PUMPMODEL

D4-0095

D4-0140

D5-0200

D5-0290

D5-0290

D6-0420D6-0600

B

170520*170530*

190550*190550*190

225225

HB

115

115

135

135

135

155155

HT

211

211

255

255

255

295295

E

20

20

20

20

20

2020

D

307

307

371

371

371

429429

The above dimensions are for guidance only and should not be used for installationpurposes. Certified dimensions are available upon request.

* = Dimensions when priming adaptors are fitted

'A' PortSize

3.3 Pump Dimensions

J

63

63

70

70

70

7070

7

Operating Manual

Pump Unit - Pump complete with DriveUnit

Pump Model

D4-0079D4-0095D4-0140

D5-0168D5-0200D5-0290

D6-0353D6-0420D6-0600

Bareshaft PumpKG

110113130

170176192

281289300

Pump with Drive UnitKG

147150220

264270350

392400530

Bareshaft Pump

The above weights are for guidance only and will vary depending upon thespecification of the pump, baseplate and drive unit.

3.4 Pump and Pump Unit Weights

8

Operating Manual

PumpRef

D4-0079D4-0095D4-0140

D5-0168D5-0200D5-0290

D6-0353D6-0420D6-0600

Displacementlitres/rev

0.790.951.40

1.682.002.90

3.534.206.00

MaximumSpeedWater(rpm)

750500500

600500500

500500500

Maximum Capacityat Maximum Speed

m³/hr

35.628.542.0

60.560.087.0

106.0126.0180.0

The following table details the pump capacitiesfor the pump models. This figure will changedepending upon speed, pressure, temperatureand product being pumped.

3.5 Pump Displacement and Capacities

9

Operating Manual

Depending on your requirements the pumpand drive (if supplied) may arrive mounted ona baseplate. Our standard baseplates havepre-drilled fixing holes to accept base retainingbolts.

To provide a permanent, rigid support forsecuring the pump unit a foundation is required,this will also absorb vibration, strain or shock onthe pumping unit.

Foundation Size

The foundation should be approximately150mm longer and wider than the mountingbase of the unit. The depth of the foundationshould be proportional to the size of the pumpunit (pump complete with drive and baseplate).For example, a large pump unit foundationdepth should be at least 20 times the diameterof the foundation bolts.

Bolt Location Dimensions

The location and sizes of the relevant boltingdown holes can be provided on a certifieddrawing from your supplier.

Typical Foundations Bolts

The drawing below shows two methods forfoundation bolt retaining. The sleeve allows for'slight' lateral movement of the bolts after thefoundation is poured. Use rag or paper toprevent the concrete from entering the sleevewhile the foundation is poured. A minimum of14 days is required to allow the curing of theconcrete prior to operation.

D = Diameter of foundation bolts

4.2 Pump and Base Foundations

Before the pump is installed it is advisable toconsider the following:

Always - Ensure that the mountingsurface is flat to avoid distortionof the baseplate. This willcause pump/motor shaftmisalignment and pump/motorunit damage.

Check - pump shaft to motor shaftalignment once the baseplatehas been secured and adjustas necessary.

Note : Always allow at least one metre forpump access/maintenance all around the pump.

Weight - Consider the weight of thepump, drive and lifting gearrequirements.

- Ensure that there is anadequate electrical supplyclose to the pump drive unit.This should be compatible withthe electric motor selected.

4.3 Installation

Baseplate FixingHoles

ElectricalSupply

11

Operating Manual

Parallel Misalignment

Angular Misalignment

When installing the pump and drive unit, it isessential to ensure that the coupling is nottwisted during installation. The main cause ofmisalignment is by fitting the baseplate to anuneven surface.

Check the maximum angular and parallelallowable misalignments for the couplingsbefore operating the pump.

RecommendedCoupling Type Maximum Parallel Maximum Angular

Misalignment Misalignment

Size mm Degrees

1 0.2 David Brown ± 1.5°

2 0.3 Nylicon Flexible (Per Gear in Mesh)

3 0.4

FL63 0.25

FL80 0.75° William Kenyon

FL112 0.3Flexilok

FL125 0.4 1.0°

FL160 0.5

F40 1.1

F50 1.3Fenaflex

F60 1.6 Flexible Tyres 4°

F70 1.9

F80 2.1

F90 2.4

Note : The above table indicates the common coupling types used on the pump ranges.Details for other coupling types will be available on request.

4.4 Coupling Misalignment

12

Operating Manual

Belt Small Pulley RecommendedSection Diameter Deflection Force Range Newtons

mm min max

XPZ SPZ

XPA SPA

5660-6367-7175-8085-95

100-125132-180

80-125132-200

7 8 910111316

1822

11131415161924

2731

An incorrectly tensioned belt will cause beltslip and short belt life. An excessivelytensioned belt will overload both belts andbearings. Always use a belt tension gaugefo setting up.

Isolate the drive unit and pump from all powerand control supplies before attempting to workon adjusting the belts.

1. Measure the span length.

2. Calculate the required deflection: ('x')

100mm span length = 1mm deflection

therefore :

400mm span length = 4mm deflection

3. Refer to the table for recommendedminimum and maximum deflection forcefor small pulley diameter range.

To convert Newtons to pounds forcemultiply by 0.2248.

To convert Newtons to kilogrammesforce multiply by 0.1020.

4. Use a belt tension gauge with the figuresto determine the belt adjustment required.

5. Belt tension adjustment is achieved byadjusting the nuts on the pedestal frame.

6. Finally check that all nuts are re-tightenedand the belts can move 'freely' by hand(depending upon pump size and systemdesign).

7. Ensure the pulleys are kept vertically andhorizontally to each other and aligned asper diagrams (A) and (B).

Force 'X'

Span

Note : The above table indicates the commonpulley types used on the pump ranges. Detailsfor other pulley types will be available on request.

(B)(A)

4.5 Pulley Belt Tension Adjustment

13

Operating Manual

Pipework Support

Pipework Support

All pipework must be supported. The pumpmust not be allowed to support any of thepipework weight.

Remember - Pipework supports must alsosupport the weight of theproduct being pumped.

Always :-

Have - Short straight suction lines toreduce friction losses in thepipework thereby improvingthe NPSH available.

Use - Long radius bends whereverpossible.

Provide - Isolating valves on each side of thepump to isolate the pump whennecessary.

Keep - Pipework horizontal whereapplicable to reduce air locks.Include eccentric reducers onsuction lines.

Check - Coupling alignment duringinstallation to highlightpipework alignment/supportproblems.

Install - A liquid trap around to pump toassist in priming. (See below)

Non return valve

Fluid trapped to maintainprime

4.6 Pipework

14

Operating Manual

Changing the Oil :-

First change - After 150 hours of operation.

Next change - Every 3000 hours of operation.

Only use the oil types recommended by yoursupplier.

Oil Filling - Fill with oil through thefiller plug to the levelindicated in the sightglass.

Oil Filled

-20° C to +130° C

BP Energol GR - XP150Castrol Alpha SP150

Mobil Gear 629Shell Omala 150

Texaco Meropa 150Esso Spartan EP150

Total

1.10

2.00

3.60

BottomChamber

Litres

0.75

1.38

2.30

TopChamber

Litres

0.35

0.62

1.30

PumpModel

D4

D5

D6

Pumps specified oil filled :-

The pump will not be supplied with oil thereforethe table below must be used to select arecommended oil.

Note : Ensure all ancillary drive units arelubricated according to the manufacturersinstructions.

5.0 Commissioning

5.1 Recommended Lubricants 5.2 Lubricating the Pump

15

Operating Manual

5.3 Flushed Seal Arrangements

A flushed seal arrangement is fitted in order tocool the seal area.

It is important that:-

- The flush is correctly connected.(See overleaf).

- A compatible flushing fluid is used.

- The fluid is supplied at the correctpressure and flow rate.

- The flush is turned on at the same time/prior to starting the pump, and turned offat the same time/after stopping the pump.

5.4 Connecting the Flush5

The following equipment is stronglyrecommended when using a flushing system.

- Control valve and pressure gauge, toenable the correct flushing pressure to beobtained and monitored. (A constant flowvalve can be used).

- Isolation valve and check valve, so thatthe flush can be turned off, and to stopany unwanted substances flowing in thewrong direction.

- A method of visibly indicating flushingfluid flow e.g. using a tun dish.

16

Operating Manual

E

Note :- The pipework and fittings arenot supplied with pump.

5.5 Flushing Pipework Layout

This suggested arrangement is for singlemechnical seals. If the pump is fitted withdouble mechanical seals or packed glandsthe pressure gauges and control valvesshould be fitted on the outlet side of thesystem.

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Operating Manual

Single Mechanical Seal - 0.5 Bar maximum.Any further increase in pressure will result in lipseal failure.

Double Mechanical Seal/Packed Gland Seal- 1.0 bar higher pressure compared to thedischarge pressure of the pump. If the dischargepressure fluctuates set the flushing pressure tosuit the maximum condition.

For guidance the pressure at the seal isapproximately 2/3 of the pumping pressure.

The flushing flow rate must be adequate toensure that the temperature limitation of theseals is not exceeded. Contact your supplierfor further information on the recommendedflow rate for the product seal fitted.

The choice of flushing fluid is dependant uponthe pumping media and duty conditions i.e.pressure and temperature. Usually water isused for cooling or flushing water solubleproducts. For advice on selecting a suitableflushing fluid please contact the supplier.

5.6 Flushed Seal Housing Connections

5.7 Flushing Fluid 5.8 Flushing Pressure and Flow Rate

18

Pump Model Single/Double Packed Mech. Seal GlandD4 1/8” 1/4”

D5 1/8” 1/4”

D6 1/8” 1/4”

All connections BSPT or NPT as specified atthe time of order.

Operating Manual

1. Is the location of the 'stop' button clear?

2. Has the pipework system been flushedthrough to purge welding slag and anyother hard solids?

3. Have all obstructions been removedfrom the pipework or pump?

4. Are the pump connections and pipeworkjoints tight and leak-free?

5. Is there lubrication in the pump anddrive unit?

6. If your product seals require flushinghas the flushing supply been fitted?

7. Are the pipework valves open?

8. Are all safety guards in place?

9. Start then stop the pump, is the productflowing in the correct direction?

10. Are the pump speed/pressure settingsbelow the pump maximum limitations?

6.0 Start up, Shut Down and Cleaning in Place

6.1 Pump Start-up Checklist

If there are any pumping problemsrefer to the fault finding chart.

All answers should be 'Yes' before proceeding.

Yes No

19

Operating Manual

1. Turn the pump off.

2. Isolate the pump/drive unit from all powerand control supplies.

3. Close the pipework valves to isolate thepump.

4. If the pump is to be dismantled refer to thedismantling section.

Discharge Suction Suction

Top ShaftDrive Position

Bottom ShaftDrive Position

Discharge

6.2 Pump Shut Down Procedure

6.3 Direction of Rotation

The direction of flow is dictated by the directionof rotation of the drive shaft. Reversing thedirection of rotation will reverse the flowdirection. Top and bottom shaft drive pumpshave opposite flow directions as illustrated.

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Operating Manual

Part Description

Lip Seal Drive End'O' Ring Front CoverLip Seal Gland EndRotors'O' Ring Rotor Sealing'O' Ring Rotor CapProduct Seals

Quantity

2122222

It is advisable to install pressure gauges eitherside of pump so that any problems within thepump/pipework will be highlighted.

Your weekly schedule should include:

Checking the oil level in the gearcase

Checking the mechanical seals forleakage and replacing as necessary.

Geasing the mechanical sewage seal (iffitted).

Adjusting the packed glands to controlleakage.

Checking the oil seals for leakage.

Check pumping pressures.

The following table details the recommendedspare parts which should be retained within yourmaintenance stock.

7.0 Maintenance and Inspection

7.1 Maintenance and Schedule 7.2 Recommended Spare Parts

21

7.3 Urethane Rotors

For pumps fitted with urethane covered rotors,please ensure that the rotors are not leftimmersed in pumped media inside the pumphead for long periods (20 days max), withoutthe pump being used or rotated.

Failure to adhere to this could lead to rotorswelling, thereby causing possible rotorjamming in the pump head and poor pumpperformance. It should be noted that urethanerotors should not be allowed to come into anycontact with any hydrocarbons, ketones orethers, as these products will cause rotors toswell.

Operating Manual

Dismantling and Assembly of the Pumphead

You will need - Allen keysSpannersSocket setWooden wedgeSoft malletCleaning hoseSilicon greaseTorque wrenchRotor clamp tool (supplied with pump)

Dismantling and Assembly of the Gearbox

You will need - A Work Shop equipped with:

A heavy duty viceA press and pressing toolsLifting gearInduction heaterA method of lubrication collectionLever soft endedWooden wedge'C' spannerLiquid gasketPermabond 145 (or equivalent)Torque wrench

Pump Head Gearbox

7.4 Maintenance Tools

22

Operating Manual

'O' Ring 'B'TLA

'O' Ring 'A'Rotor Cap

Note : 'O' ring 'A' is fitted in a recess on pumpsD5 and D6.

8.1 TLA Mounting Instructions

When fitting a TLA it is recommended that :-

1. The TLA is lightly oiled on all surfaces toassist in achieving the correct torque valueand to aid its release when removing.

2. Once fitted into its working position andbefore tightening, a temporary rotor clamp,supplied with the pump, should be usedto ensure the rotor with TLA is positivelyabutted against the shaft shoulder. Thiswill ensure that rotor clearance on both itsfront and rear are maintained.

8.0 Disassembly

Rotor retention on all pumps in the Series Drange is by Torque Locking Assembly (TLA) withflush fitting rotor caps. The rotor spline area issealed with three O'rings per rotor (A, B, & C),one (A) between the shaft and rotor, and two (B& C) seated in the rotor cap. The rotor caps areretained by socket head cap screws. The TLA'sshould be tightened to the recommended torquevalues.

3. Using the rotor clamp with the rotorcorrectly positioned on the shaft and theTLA in place, a suitable screw is putthrough the centre hole in the clamp andtightened into the end of the shaft. Thiswill hold the rotor in place and the TLAscrews may now be tightened through theaccess slots in the clamp.

4. With the rotor clamp secured in place theTLA screws can be torqued up to thecorrect settings. To obtain best resultsit is recommended the screws aretightened in a diametrically opposedpattern, repeating until correctly set.

8.2 TLA Release Instructions

Loosen the socket head cap screw and removethe rotor cap ensuring that the two sealingO'rings are not lost. If the rotor cap does notrelease easily it can be removed by gentlyscrewing a suitable screw into the thread in thecentre hole of the rotor cap.

Loosen the TLA in several stages and in adiametrically opposite sequence. The loosenedTLA can now be removed.

To extract the TLA from the rotor, only removethe two screws which are fitted with washers,carefully screw 8mm x 50mm bolts into theholes (these holes have only 3-5 threads) andpull out the TLA.

'O' Ring 'C'

23

Operating Manual

Torque Values for Rotor Torque Locking Assemblies

Pump Torque Key SizeNm (lbft) mm

D4 4.1 (3.0) 3

D5 8.5 (6.3) 4

D6 14.0 (10.3) 5

RotorTLA

Rotor Clamp

Screw

Access to TLAthrough slots

8.3 Rotor Retention: Torque Locking Assembly

24

Operating Manual

Before starting to dismantle the pumpAlways:-

Purge -

the pump and system if any noxious productshave been pumped.

Isolate -

pump/drive unit from all power and controlsupplies.

Close -

pipework valves to isolate the pump

Disconnect -

the pump from the drive unit.

Read this section first beforecontinuing to dismantle the pump

9.0 General Maintenance

9.1 Before Dismantling the Pump

25

Operating Manual

Typical rotor extraction tool

master lobe

spline teeth

9.2 Removing the Rotors

1. Before starting to dismantle the pumpheadisolate the driver/pump from all power andcontrol supplies, purge the system if anynoxious products have been pumped.Read the safety section carefully.

2. Ensure isolating valves to the pump areclosed.

3. Carefully loosen the front cover retainingscrews, there may still be residual pressurein the system.

4. Remove the front cover retaining screwsand take off the cover. D5 and D6 pumpsmay have hinges fitted to the front covers.Having removed the front cover retainingscrews the cover can be swung to oneside.

5. Flush out the pumphead with a suitablecleaning agent before continuing.

6. Remove the rotor cap and torque lockingassemblies.

7. Before removing the rotors their positionshould be noted such that they can bereplaced easily. Mark the master rotorlobe, which centre line corresponds withthe rotor spline teeth. See below.

8. Extract the rotors which should slide outfrom the splines. An internal groove isprovided in the front of the rotor into whicha suitable tool may be inserted to aidextraction. An illustration of a typical tool isshown below.

26

Operating Manual

Shims

Shims

9.3 Removing the Rotorcase

1. Before proceeding disconnect the suctionand discharge piping.

2. Remove the rotors as described previously.On pumps D5 and D6 shut the hinged frontcover (where fitted) and loosely fasten withfront cover screws.

3. Loosen gland followers or when fitted witha flushed seal arrangement remove thehousing retaining nuts and ease thehousing away from the rotorcase.

4. Remove the rotorcase retaining nuts, andtatp the rotorcase forwards with a soft malletuntil it clears the locking dowels. If thepump is fitted with mechanical seals, caremust be taken to support the rotorcase asit comes off the dowels otherwise themechanical seals may be damaged.

5. Between the rotorcase and gearcase,preshaped plastic shims are used to adjustthe rotor clearances. These must bereplaced exactly as removed, otherwiseexcessive wear or damage may occur tothe rotors and/or rotorcase.

6. Once the rotorcase is removed the seals/gland packing can be examined.

27

Operating Manual

1. Follow the procedure for the removal ofrotors and rotorcase.

2. Remove the product seal.

3. Three socket head screws retain the sealcarrier, once removed the carrier can beextracted. As silicon sealant or a gasketis used to seal the faces the carrier mayhave to be eased off carefully with a lever.

4. Once the carriers are removed from thepump the seals can be pressed out andreplacements pressed in using a suitabledolly.

5. Ensure the surface area which the sealwill run on is free from scratches, if thesurface is scratched clean up damagedarea with a fine grade abrasive cloth.Ensure that all traces of abrasive materialare cleaned away before refitting the newoil seals.

Note : It is advisable at this point to check forbearing end play, as this may be the cause ofthe seals leaking.

Front SealCarriers

Front Seals

Large Holes

Longer Socket Head Screws

9.4 Replacing the Front Gearcase Seals

6. Before replacing the seal carriers, cleanthe old silicon sealant (if used) from therear face of the carrier and from the frontface of the gearcase. Coat the rear faceof the carrier with new liquid gasket, slideinto position and replace the three sockethead screws. It must be noted that one ofthe three screws is longer, this should beinserted in the hole which aligns with thelargest hole in the gearcase. Tighten thescrews evenly to the recommended torquevalue.

7. Reassemble the seals and rotorcase, seethe relevant sections for refittingprocedure.

28

Operating Manual

When fitting a rotorcase correct shimming iscritical. Shims are fitted between the rotorcaseand gearcase and are used to control the backclearances between the rotor and rotorcase.Plastic colour coded shims are used on all seriesD pumps. If the pump has previously beenshimmed, the old shims may be reused providedthey are replaced in their original positions. It isessential that equal shimming is used both topand bottom of the rotorcase to ensure that equalclearances are maintained across the rotorfaces.

To reassemble the rotorcase the following stepby step procedure should be used :-

- Check the seals are correctly fitted.

- If the rotorcase has previously beenshimmed, replace the old shims in theiroriginal positions.

- Alternatively, if new shims are to be fittedthe shimming process commences with'too few' shims. Fit the rotorcase andtorque up the gearcase nuts, fit the rotorsand tighten to the recommended torque.With 'too few' shims fitted measure theback clearances (the clearance betweenthe back of the rotors and rotorcase), anddetermine the additional shimming requiredto bring the clearance within tolerance.

Note : For the correct clearance dimensionsplease contact your supplier.

- Fit the additional shims, and recheck theclearances. If necessary repeat the aboveexercise until the clearances come withintolerance.

Care should be taken when sliding the rotorcaseover the shafts so as not to damage themechanical seals if fitted. When fitting the shimsensure that similar clearances are achieved bothtop and bottom of the rotorcase.

9.5 Fitting and Shimming the Rotorcase 9.6 Front Cover Reversal

The front cover of all pumps in the series D rangeis of a flat and symmetrical design thus making itreversible. Therefore, when the inside face ofthe front cover becomes worn it may be reversed.In due course both sides will become worn andthe cover will have to be replaced.

Isolate the driver/pump from all power and controlsupplies. If any noxious products have beenpumped, the system should be purged.

Ensure isolating valves to the pump are closed.Loosen and remove the front cover retainingscrews and remove the front cover.

In the case of D5 and D6 pumps loosen andremove the screws which hold the front cover tothe hinge. Be sure to retain the washers fittedunder the screw heads. Thoroughly clean thefront cover. Inspect 'O' ring and replace ifnecessary.

Before replacing front cover simply reverse itsuch that the unworn side faces the pump. In thecase of the D5 pumps ensure that the cover isorientated such that the hinge fixing holes line upwith the hinge.

In the case of D5 and D6 pumps refit the hinge tothe cover by refitting the hinge retaining screws,make sure that the washers are refitted under thescrew heads. Ensure that the ends of the hingeretaining screws are flush with the inside of thefront cover when fully tightened.

Fit front cover and tighten retaining screws to therecommended torque values.

29

Operating Manual

gearbox dismantled the pump will have tobe retimed as described in the timingadjustment section.

To refit the rotors the recommended procedureis as follows :-

- rotate the drive shaft until the keyway'suppermost (not essential).

- find the master lobe of the rotor whichcentre line is the same as that of thespline teeth. See below.

- line the master lobe up with the shaftspline and slide the rotor onto the shaft.

- find the master lobe of the remaining rotoras previously done.

- slide the rotor on so that both rotors are inthe position shown below.

Correct timing has been achieved whenthe pump rotates freely without contacttaking place between the rotors, thisshould always be checked prior to runningthe pump.

3. Replace the 'torque locking assemblies'.Refer to section 8.1 on page 23 for fulldetails.

4. Before refitting the front cover examinethe 'O'ring and replace it if damaged. Fitfront cover and tighten the nuts up to therecommended torque values.

9.7 Removal of Rear Gearcase Cover andReplacement of Seal

1. Isolate the motor, remove any coupling orVee belt guards.

2. If the pump is direct coupled it will benecessary to disconnect the coupling andremove the pump from the baseplate beforeremoving the gearcase cover.

3. If the pump is belt driven, release the tensionon the belts and remove them, remove thepulley and drive key.

4. Drain the oil from the pump.

5. Remove the retaining screws and thenremove the gearcase cover by sliding italong the drive shaft. As the cover issealed to the gearcase with a liquid gasketit may require a sharp tap with a mallet andpunch to break the joint.

6. With the cover removed, press out the oilseal from the cover and replace with a newseal.

7. Clean the faces of both the gearcase andthe end cover, coat the faces with a suitableliquid gasket and refit the end cover.Replace the retaining screws thencentralise the lipseal on the shaft beforetightening to the recommended torquevalue.

8. Refill the pump with oil.

1. All rotors in the series D pump range havesealing 'O' rings as described previously.Check the condition of the 'O' rings and fitnew rings if necessary.

2. Rotors are fully interchangeable. Whenrefitting the rotors correct timing is achievedby replacing the rotors in exactly the samepositions as when removed. If the gearshave been removed or the

9.8 Refitting the Rotorcases

centreline of lobe spline toothcentreline of

shaft

Master lobe

Master lobe

30

Operating Manual

Wearplates

1. Before fitting new wearplates thoroughlyclean the inside of the rotorcase where thewearplates will be sealed. In addition wipeclean the rear face of the new wearplates.

2. The new wearplates will be supplied withthe studs already attached.

3. Just prior to fitting the wearplates applysilicon sealant, or similar, to the wearplatestuds.

4. Insert the new wearplates through the frontof the rotorcase ensuring that the studspass through the holes in the rear of therotorcase.

5. Assemble nuts to the studs at the rear of therotorcase and tighten to a torque of 8Nm(5.9 lbft).

Replacing Wearplates

All pumps in the series D range can be fitted withwearplates . When worn the wearplates can bereplaced thus increasing the life of the pump.

Wearplates can be replaced without removingthe rotorcase, but access to the wearplateretaining nuts may be increased if the rotorcaseis removed.

Removing Old Wearplates

1. Remove the front cover and rotors asdescribed. If considered necessary,remove rotorcase.

2. Loosen and remove the wear plate studretaining nuts from the rear of the rotorcase.

3. Next the wearplates, with the studs stillattached, may be removed from the front ofthe rotorcase where the wearplates will beseated.

Fitting New Wearplates

9.9 Wearplates

31

Operating Manual

Pump Torque Key SizeNm (lb/ft) mm

D4 14 (10) 5 D5 35 (26) 6 D6 35 (26) 6

Timing Gears

TLA

10.0 Gearbox Components

10.1 Timing Gears

Each pump is fitted with a pair of timing gears,which are located in the rear of the gearcase andensure synchronisation of the rotors, such thatunder normal working conditions they will notcontact one another.

The timing gears on pumps in the D range areretained using Torque Locking Assemblies (TLA)similar to those used to retain the rotors. Themethod of correctly tightening the TLA's is thesame as for the rotors as previously described.

32

Operating Manual

The rotor timing (synchronisation) is set-up inthe factory. If the rotors becomeunsynchronised, they may be retimed usingthe following procedure.

The cause of the fault should beestablished and eliminated before

proceeding.

To adjust the timing of the rotors, first removethe gearcase end cover, once the cover isremoved the timing gears will be exposed.

To retime the rotors, only one of the timing gearretainers need to be released sufficiently, toallow the rotors to be tapped into a positionwhere they are synchronised. The rotors arecorrectly synchronised when the clearances atthe measurement points are equal.

Use feeler gauges to measure the clearancesat the positions illustrated, and adjust untilequal, the pump is then correctly timed. Tightenthe screws of the torque locking assembly tothe correct values and replace the gearcasecover.

To remove the timing gears the followingprocedure is recommended.

1. Drain lubricant.

2. Remove rear gearcase cover.

3. Release torque locking assemblies.(refer to page 23 - 8.2)

4. An extractor tool may be required to pullthe gear off. Because the gearcase hastwin lubricated chambers lubricant maydrain out when the top gear is removed.

The bearing lip seal fits behind the top shaftrear bearing housing. The lip seal runs on aboss at the back of the timing gears, andprevents the top chamber lubricant from draininginto the bottom chamber. If the lip seal is to bereused care should be taken when extracting itnot to damage the sealing edge, otherwise anew lip seal should be fitted. To refit a seal, itshould be pressed evenly into the hole, and aflat plate or dolly used to drive it home.Measurement

PointMeasuementPoint

Diagram of Rotors Showing Timing

10.5 Fitting the Timing Gears

1. Fit the rotors to the shafts to establish thetiming.

2. Check that the bearing lip seal is fitted.Check that the boss on the back of thegear is smooth, and smear some lubricantonto it.

3. Slide on the gears. Where gears aremarked as pairs they should be refittedwith the timing marks aligned.

4. Fit the torque locking assemblies, andtorque 'one' of them up. Adjust the timing,before tightening up of the last gear.

10.2 Timing Adjustment

10.3 Timing Adjustment

Removing the timing gears is a reasonablysimple operation though difficulty may beexperienced in sliding the gears off the shaft. Ifthis is the case an extractor tool may be required.For this purpose threaded holes are provided inthe gears.

10.4 Lip Seal - Removal & Refitting

33

Operating Manual

RotorEnd Gear

End

Spacer Spacer

Note Direction of Tapers

Bearing Assembly

1. Remove rotorcase front cover, rotor androtorcase.

2. Remove product seals.

3. Remove the gearcase rear cover, timinggears and drain lubricant.

4. Remove the gearcase front seal retainersand seals.

5. The shaft assemblies can now be removedthrough the front end of the gearbox, a softfaced mallet may be used to tap them out.The top chamber can now be completelydrained. Ensure that the spacer located inthe front bottom shaft bearing housing isretained for refitting.

The series D range of pumps utilise taper rollerbearings which are arranged in two sets of doublebearings front and back, assembled withindividual spacers. Refer to the explodeddiagrams at the rear of the manual.

10.6 Shaft Removal

10.7 Bearings - General

1. Load shaft into vice in a vertical positionand apply anti-seize compound to thebearing diameters.

2. Working first on the front set of bearings,use an induction heater or oil bath to heatthe front bearing cone to 110ºC. Pass thebearing over the rear bearing diameterand ensure a positive fit on the frontbearing diameter against the shaftshoulder. The bearing taper should betowards the gear end of the shaft.

10.9 Fitting Bearings to Shaft

To remove the bearings, undo the notchedbearing nut using a C- spanner, the bearingassembly can now be dismantled. The bearingcones are shrunk onto the shaft and will requirepressing off.

10.8 Bearings Removal

3. Locate outer shell of bearing onto thecone just fitted.

4. Locate bearing spacer onto shell just fitted.

5. Locate rear bearing shell, of front set ofbearings, onto the spacer.

6. Heat rear bearing cone to 110ºC and fit tobearing diameter. The taper should betowards the rotor end of the shaft.

7. Allow bearings to cool.

8. Locate shaft in vice in horizontal position.

9. Apply Permabond grade 145 sealant orequivalent to the shaft front lock nut threadand screw front lock nut onto the shaft.Whilst continuously rotating both bearingsand spacer, torque up the bearing lock nutuntil the spacer cannot be moved radially(off the shaft centre line) by finger pressurealone, but can be moved with a light blowof a hammer.

10. Repeat the above procedure for the rearset of bearings, but in this case torque upthe lock nut until the spacer can be justmoved by finger pressure alone.

34

Operating Manual

1. Replace shaft abutment spacer into thefront bottom bearing housing of thegearcase, between the front bearing andthe housing.

2. Fit auxiliary shaft into gearcase.

3. Fit drive shaft into gearcase.

4. Fit seal retainers to the gearcase withoutsilicon sealant at this stage, and torquethe cap screws to their recommendedvalue.

5. Fit rotors or shaft abutment blocks to theshafts and torque the rotor torque lockingassemblies to the recommended value.

6. Using a depth micrometer measure fromthe front face of the bottom rotor to thefront face of the top rotor, and record theaxial displacement of the rotor abutmentshoulders. When measuring off a pair ofrotors it is important to compensate forany small differences there may be in therotor lengths.

7. The axial displacement should be lessthan 0.012mm, if it is not the bottom shaftshould be removed and the spacer groundor an appropriate spacer fitted to give aaxial displacement of not greater than0.012mm.

8. Once both shaft shoulders are withintolerance of each other, remove both sealretainers, fit the front oil seals, apply siliconsealant to the retainer face and torque up.Recheck to ensure alignment.

9. With the shafts installed the timing gearsand front end of the pump can be refitted.The pump should now be timed, aspreviously described.

0.012

0.000

10.10 Shaft Replacement

Gearboxes are assembled with the top shaftbearing located against a machined surface inthe bearing housing, and the bottom shaftbearings butting against a spacer fitted into thefront bearing housing. When a new gearbox isbeing built this spacer is initially oversized,such that the axial displacement in the rotorabutment shoulders can be measured and theappropriate spacer fitted, or the existing spacerground to suit. When rebuilding a used gearboxthe axial displacement should be checked,however, it will normally be within tolerance,0.012mm.

Rotor Abutment Alignment

Note : The axial displacement can be in eitherdirection as long as it is within tolerance.

Rotor orAbutmentBlock

35

Operating Manual

Item Description

1 Stationary Face 'O' Ring 2 Stationary Face 3 Rotary Face 4 Shaft 'O' Ring 5 Wave Spring 6 Drive Ring

The seal comprises of a rotary face which issealed to the shaft by an 'O' ring. A wavespring(s) provide a force to maintain face toface contact. Rotation is provided by socketset screws which are tightened onto the shaft.The stationary face is located in the rotorcaseand is prevented from rotating by three pins.

Seal faces are extremely brittle.Take extreme care when handling.

Removing the Single Mechanical Seal

1. To release the seal from the shaft loosenthe socket set screws.

2. Remove the rotorcase with the stationarysealing face still within its bore, takingcare not the chip the face.

3. Carefully remove the remaining part ofthe seal from the shaft.

Fitting the Single Mechanical Seal

1. Use a solvent to wipe the lapped surfaceof the seal faces until perfectly clean,being extremely careful not to scratch thefaces.

2. Lightly lubricate the 'O' ring and shaft endwith a silicon grease (food quality ifnecessary).

3. Firmly press the stationary face 'O' ringonto the stationary face edge and locatewithin the rotorcase bore over the rollpins.

4. Mark the shaft to indicate the seal settinglength.

5. Push the 'O' ring within seal assemblyface bore and gently slide the seal ontothe shaft until it reaches the settingposition.

6. Tighten the socket set screws.

ShaftAbutmentSpacer

11.0 Product Seals Removal and Fitting

11.1 Single Mechanical Seal

36

Operating Manual

The seal comprises of a rotary face which issealed to the shaft by an 'O' ring. A wavespring(s) provide a force to maintain face toface contact. Rotation is provided by socketset screws which are tightened onto the shaft.The stationary face is located in the rotorcaseand is prevented from rotating by three pins. Aseal housing with lip seal encloses the seal andruns on a shaft sleeve.

Seal faces are brittle.Take exteme care when handling.

Removing the Single Flushed MechanicalSeal1. To release the seal from the shaft loosen

the socket set screws through the flushingconnection.

2. Remove the seal housing retaining nutsand pull it away from the rotorcase.

3. Remove the rotorcase with the stationarysealing face still within its bore, takingcare not to chip the face.

4. Carefully remove the remaining part ofthe seal from the shaft followed by theseal housing, lip seal and spacer.

Item

1234567891011

Description

Stationary Face 'O' RingStationary FaceRotary FaceShaft 'O' RingWave SpringDrive RingSpacer O' RingSpacerGasketSeal HousingLip Seal

11.2 Single Flushed Mechanical Seal

Fitting the Single Flushed Mechanical Seal

1. Press the lip seal into the seal housing.

2. Lubricate spacer 'O' ring, fit into spacerand push onto the shaft.

3. Carefully guide the seal housing with lipseal over the spacer.

4. Use a solvent to wipe the lapped surfaceof the faces until perfectly clean, beingextremely careful not to scratch the faces.

5. Lightly lubricate the 'O' ring and shaft endwith a silicon grease (food quality ifnecessary).

6. Firmly press the stationary face 'O' ringonto the stationary face and locate themwithin the rotorcase bore over the rollpins.

7. Push 'O' ring within seal face bore andgently slide the seal onto the shaft until itreaches the spacer.

8. Tighten the socket set screws through theflushing holes.

9. The rotorcase can now be refitted whilstat the same time locating and tighteningthe seal housing nuts.

37

Operating Manual

The seal consists of two rotary faces which aresealed to the shaft by 'O' rings. Rotation isprovided by socket set screws which tightenonto the shaft. The two stationary faces arelocated in the rotorcase and seal housing bores.Rotation is prevented by pins and cast lugs.Wave spring(s) provide a face to maintain faceto face contact. As seal housing attached tothe rotorcase encloses and sets the seal.

Seal faces are brittle.Take extreme care when handling.

Removing the Double Mechanical Seal

1. Using the flushing holes loosen each ofthe socket set screws.

2. Remove the seal housing retaining nutsand pull back the seal housing away fromthe rotorcase.

3. Carefully remove the rotorcase with thestationary face still fitted.

4. Slide the rotary faces off the shaft followedby the seal housing with remainingstationary face.

Description

Stationary Face 'O' RingStationay FaceRotary FaceShaft 'O' RingWave SpringDive RingWave SpringShaft 'O' RingRotary FaceStationary FaceGasketStationary Face 'O' RingSeal Housing

Item

12345678910111213

RotorcaseSide

GearcaseSide

Fitting the Double Mechanical Seal

1. Use solvent to wipe the lapped surface ofthe seal faces perfectly clean, beingextremely careful not to scratch the faces.

2. Lightly lubricate the 'O' rings and shaftend with silicon grease (food quality ifnecessary).

3. Firmly press on the 'O' rings to thestationary faces and locate them withinthe rotorcase bore and seal housing.

4. Locate 'O' rings into rotary faces.

5. Carefully fit the seal housing withstationary face onto the shaft.

6. Push the rotary assembly onto the shaftuntil it sets against the seal housingstationary face.

7. Fit new seal housing gasket.

8. Carefully fit the rotorcase and tighten theseal housing nuts.

9. Tighten each of the seal socket set screwsthrough the seal housing flushing holes.

Note:- The drive ring chamfer mustbe on the gearcase side of the shaft.

11.3 Double Mechanical Seal

38

Operating Manual

39

Drip leakage is essential to preventoverheating of the gland area which willcause seal failure.

The packing rings are located within the glandhousing and are tightened onto the shaftsleeve by adjusting the gland follower. Onflushed packed glands a lantern ring replacesthe middle ring of packing. The shaft sleeveis retained to the shaft by three socket setscrews and is sealed by an 'O' ring.

Removing the Packed Gland

1. Release and pull back the gland follower.

2. Remove the rotorcase with glandhousing, packing and gland follower stillassembled.

3. Loosen the shaft sleeve socket setscrews and extract the sleeve from theshaft.

4. Inspect and replace the packing andshaft sleeve if necessary.

Fitting the Packed Gland

1. Lubricate the 'O' ring, locate in shaft sleeveand slide onto the shaft.

2. Tighten up the socket set screws, ensuringtha the drilled dimples are aligned withthe grub screws. Permabond A130 orequivalent should be used to secure grubscrews in their positions.

3. Fit gland spacer, gasket and gland housingto the rotorcase.

4. Insert the packing rings and lantern ring (ifflushed packed gland). Make sure theyare in the correct order and positionedwith the scarf joints 120° apart.

5. Loosely locate the gland follower andnuts.

6. Refit the rotorcase with packed assemblyover the shaft sleeves.

7. Adjust the packed gland see next page.

11.4 Packed Gland Arrangements

Packed Gland

Item Description

5 Gasket 6 Gland Housing 7 Gland Follower 8 Ring Slinger

Item Description

1 Shaft Sleeve O' Ring 2 Shaft Sleeve 3 Spacer 4 Packing Rings

Operating Manual

Item Description

1 Shaft Sleeve 'O' Ring 2 Shaft Sleeve 3 Spacer 4 Packing Rings 5 Lantern Ring

Item Description

6 Gasket 7 Gland Housing 8 Gland Follower 9 Ring Slinger

Adjusting the Packed Gland

Drip leakage is essential to preventoverheating of the gland area which willcause seal failure.

Important :Stop and remove gland guard for checkingtemperature of housing and observing leakage.Always replace the guard before re-starting.

1. Lightly tighten up the gland follower.

2. Flood the pumphead and determine if thegland leakage is acceptable. Tighten thegland follower nuts until an acceptableleakage is achieved.

3. Start the pump and allow to run for 10minutes. If the gland becomes significantlyhotter than other parts of the pump, thegland is too tight.

4. Stop the pump and allow it to cool thenrepeat the above until the glandtemperature is stable and gland slightlyweeping.

5. Run the pump at 10 minute intervalstightening the gland follower nuts by a 1/6 ofa turn until the leak is at an acceptablerate.

Packed Glandwith Flush

11.5 Packed Gland Adjustment

40

Operating Manual

The ACS type cartridge single mechanical sealis a bespoke seal for use mainly in arduousapplications. The mechanical seal should not bedisassembled without the use of special tools.The assembly is pre-loaded and incorrectdisassembly may cause personal injury as wellas invalidate any warranty.

Note:When seals are retro-fitted to replace AESunits, the spacer must be removed so theACS seal can be fitted direct to the pumpcasing.

Fitting Instructions:1. Check the seal has the gasket fitted.2. Slide seal onto shaft of pump as far back

as it can go.3. Repeat above for second shaft.4. Assemble pump body to gearbox housing

and tighten retaining bolts fully.5. Slide one seal towards the pump body and

ensure seal spigot enters seal area recessin pump body squarely.

6. Fit M10 nuts and spring washers to studsand tighten seal body to pump body.

7. Tighten seal to shaft by 3 x M8 (75mm unit)or M5 (45/55mm units) grub screws indrive collar (centralise sleeve to shaft bylightly tightening grub screws as firstoperation, then re-tighten to final torque of15 Nm for M8 or 4.5 Nm for M5).

8. Undo setup screws and remove completelywith setup washers (retain washers andscrews for future maintenance use onpump).

9. Repeat steps 5 to 9 for second seal.

Seal Removal:Removal of the seal assembly should becarried out in reverse order to fitting of theseal.

11.6 Cartridge Mechanical Seal

41

Operating Manual

DIA

GN

OSI

S W

ILL

BE

GR

EATL

Y A

SSIS

TED

BY

TAK

ING

ON

-STR

EAM

PR

ESSU

RE

REA

DIN

GS

AT

THE

PUM

PS IN

LET

AN

D O

UTL

ET P

OR

TS

12.0 Faults, Causes and Remedies

42

Operating Manual

GlandPackingSection

(Square)

mm

88

88

88

Numberof Ringsper Seal

WithoutFlush

44

44

55

WithFlush

33

33

44

GlandPackingSection

(Square)

mm

6.56.5

6.56.5

88

WithoutFlush

55

55

55

WithFlush

33

33

33

MechSeal

SealSize

4545

5555

7575

Number ofRings

per Seal

Standard

PumpModel

D4

D5

D6

Packed Glands

USA

PumpModel

D4-0095

D4-0140

D5-0200

D5-0290

D6-0420

D6-0600

Litres/rev.0.95

1.40

2.00

290

4.20

6.00

I gal/100 rev.

20.9

30.8

44.0

63.8

92.4

132.0

US gal/100 rev.25.0

36.8

52.6

76.3

110.5

157.8

Connection Sizeinternational stds

bar5.0

5.0

5.0

5.0

5.0

5.0

lbf/in72

72

72

72

72

72

DifferentialPressure

inches3

4

4

46 optional

6

6

mm75

100

100

100150 optional

150

150

rev/min350

350

350

350

350

350

MaxSpeed

(Sludge)

rev/min500

500

500

500

500

500

MaxSpeed(Water)

MaxCapacity(Water)

Displacement Suction &Discharge

Connections

m³/h28.5

42.0

60.0

87.0

126.0

180.0

l/sec7.9

11.6

16.6

24.1

35.0

50.0

13.0 Technical Data

13.1 Pump Information Chart

13.2 Seal Specification Chart

43

Operating Manual

Front Seal Carriers and Rear Covers

Torque 25 Nm (19 lbft) - Key Size 6mm

Wearplates

Torque 8 Nm (5.9 lbft) - Spanner Size 10mm

Shaft Sleeve Retaining Screws

D4 Torque 4 Nm (2.9 lbft) - Key Size 3mm

D5 & D6 Torque 14 Nm (10.3 lbft) - Key Size 4mm

FrontCoverScrews

Torque

Nm lbft39 29

39 29

64 47

SpannerSizemm17

17

17

RotorTLAs

Torque

Nm lbft4.1 3

8.5 6.3

14 10.3

KeySizemm

3

4

5

GearcaseNuts

Torque

Nm lbft64 47

64 47

175 129

SpannerSizemm19

19

24

TimingGearsTLAs

Torque

Nm lbft14 10

35 26

35 26

KeySizemm

5

6

6

PumpModel

D4

D5

D6

13.3 Torque Specification Chart

44

Operating Manual

D4-0095 Priming Adaptor OptionItem No Desciption

71 Priming Adaptor 72 Gasket 73 Bolt 74 Washer 75 Nut 76 Rotorcase - Rectangular Ports

14.0 Exploded Pump Drawing and Parts List

14.1 Priming Adaptor Ports

D4-0140 Priming Adaptor Option

Item No Description

61 Priming Adaptor 62 Gasket 63 Bolt 64 Washer 65 Nut 66 Blanking Plug

45

Operating Manual

14.2 D4

Exploded Pump Drawing and Parts List

Item

123456789

1011121314151617222324252627282930313233343536373839404142434445

Description

GearcaseDowelStud, GearcaseNut, Gearcase StudWasher, Gearcase StudCover, GearcaseScrew, Rear CoverLip Seal (Drive End)ShimRotorcaseWearplateStud, WearplateNut, Wearplate'O' Ring, Front CoverCover, RotorcaseHex Head Screws, Front CoverWasher, Front CoverScrews, Front Seal Carrier, ShortScrews, Front Seal Carrier, LongLip Seals, Gland EndRotors'O' Ring, Rotor Sealing Shaft EndTorque Locking AssemblyRotor Cap'O' Ring, Rotor Cap, Small'O' Ring, Rotor Cap, LargeScrew and Washer, Rotor CapKeyShaft, DriveShaft, AuxiliaryBearing/s, FrontSpacer, BearingSpacer, Rotor AlignmentNut, BearingBearing/s, RearSpacer, BearingNut, BearingLip Seal, (Bearing)GearTorque Locking AssemblyPlug

Item

4647484950

PlugSight LevelGasketFiller Plug, OilGasket

Description

46

Operating Manual

47

Operating Manual

Item

123456789

1011121314151617222324252627282930313233343536373839404142434445

Description


48

Item

4647484950

14.3 D5



Description

Operating Manual

49

Operating Manual

Item

123456789

1011121314151617222324252627282930313233343536373839404142434445

Description


50

14.4 D6



DescriptionItem

4647484950

Operating Manual

51

Alfa Laval Ltd The information contained herein is SSP Pumps correct at the time of issue but may be Birch Road, Eastbourne subject to change without prior notice East Sussex BN23 6PQ, England Tel: +44 (0) 1323 414600 Fax: +44 (0) 1323 412515 www.ssppumps.com