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1. LS 1 OF IG a ASLAN F i A NI m _ M KA 2 F G es T see RN s ea vi F 7 KN E SEAL AREA DETAIL Figure 11 Repair Rotating Assembly PARTS LIST Rotating Assembly Pump Model RT 080 ITEM NO PART NAME QTY PART NUMBER 01 IMPELLER 01 T080 RO 01 CI 02 ak SEAL ASSEMBLY 01 T080 RO 02 03 SEAL PLATE 01 T080 RO 03 04 gt INBOARD OIL SEAL 01 T080 RO 04 05 mA SEAL PLATE GASKET 01 T080 RO 05 06 BEARING HOUSING 01 T080 RO 06 07 gt INBOARD BALL BEARING 01 T080 RO 07 08 VENTED PLUG 01 T080 RO 08 09 gt OUTBOARD OIL SEAL 01 T080 RO 09 10 IMPELLER CAPSCREW 01 T080 RO 10 11 AIR VENT 01 T080 RO 11 12 IMPELLER WASHER 01 T080 RO 12 13 HEX HEAD CAPSCREW 04 T080 RO 13 14 LOCKWASHER 04 T080 RO 14 15 BEARING CAP 01 T080 RO 15 16 SHAFT KEY 01 1080 RO 16 17 IMPELLER SHAFT 01 T080 RO 17 18 BEARING RETAINING RING 01 T080 RO 18 19 OIL LEVEL SIGHT GLASS 01 T080 RO 19 20 PIPE PLUG 01 T080 RO 20 21 m BEARING CAP GASKET 01 T080 RO 21 22 amp gt OUTBOARD BALL BEARING 01 T080 RO 22 23 BEARING HOUSING DRAIN PLUG 01 T080 RO 23 24 SEAL CAVITY DRAIN PLUG 01 T080 RO 24 25 HEX HEAD CAPSCREW2. Figure 3 Valve in Open Position Figure 4 Valve in Closed Position During the priming cycle air from the pump casing flows through the bypass line and passes through the Air Release valve to the wet well Figure 3 When the pump is fully primed pressure resulting from flow against the valve diaphragm compresses the spring and closes the valve Figure 4 The valve will remain closed reducing the bypass of liquid to 3 8 to 19 litres per minute until the pump loses it s prime or stops fully closed Be sure the bypass line is directed back to the wet well or tank to preventhazardous spills Some leakage 3 8 to 19 litres per minute will occur when the valve is WARNING When the pump shuts down the spring returns the diaphragm to its original position Any solids that may have accumulated in the diaphragm chamber settle to the bottom and are flushed out during the next priming cycle NOTE The valve will remain open if the pump does not reach its designed capacity or head Valve closing pressure is dependent upon the discharge head of the pump at full capacity The range of the valve closing pressure is established by the tension rate of the spring as ordered from the factory Valve closing pressure can be further adjusted to the exact system requirements by moving the spring retaining pin up or down the plunger rod to increase or d
3. Clean the bearing housing shaft and all component parts except the bearings with a soft cloth soaked in cleaning solvent Inspectthe parts for wear or damage and replace as necessary Most cleaning solvents are toxic and flammable Use them only in a well ventilated area free form excessive heat sparks and flame Read and follow all precautions printed on solventcontainers Clean the bearings thoroughly in fresh cleaning solvent Dry the bearings with filtered compressed air and coat with light oil Bearings must be kept free of all dirt and foreign material Failure to do so will greatly shorten bearing life DO NOT spin dry bearings This may scratch the balls or races and cause premature bearing failure Rotate the bearings by hand to check for roughness or binding and inspect the bearings balls If rotation is rough or the bearing balls are discoloured replace the bearings The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the bearing housing Replace the bearings shaft or bearing housing if the proper bearing fitis not achieved If bearing replacement is required remove the outboard bearing retaining ring 18 and use a bearing puller to remove the bearings from the shaft Press the inboard oil seal 7 from the bearing housing S haftand Bearing Reassembly and installation Figure 11 Page 23 Clean the bearing housing shaft and all component parts except the bearings
4. Figure 9 Pump Performance Curve m3 h m 10 08 06 04 02 00 NPSH Net Positive Suction Head Based on 21 C clear water at sea level with minimum suction lift Since pump installations are seldom identical your performance may be different due to such factors as viscosity specific gravity elevation temperature and impeller trim Pump speed and operating condition points must be within the continuous CAUTION performance range shown on the curve Remko 20 SECTION DRAWING Z p gt V A FNS A N N gn L WW x DA Y Tm i a is I m ENS j j je Z f j Z 7 7 Z X Z Z lt Z a I 4 gt Figure 10 Pump Model PARTS LIST Pump Model RT 080 ITEM NO PART NAME QTY PART NUMBER 01 PUMP CASING 01 T080 PU 01 Cl 02 sk REPAIR ROTATING ASSEMBLY 01 T080 PU 02 03 SUCTION FLANGE 01 T080 PU 03 04 PIPE PLUG 01 T080 PU 04 05 HEX HEAD CAPSCREW 04 T080 PU 05 06 LOCKWASHER 04 T080 PU 06 07 A DISCHARGE FLANGE GASKET 01 T080 PU 07 08 DISCHARGE FLANGE 01 T080 PU 08 09 NAME PLATE 01 T080 PU 09 10 DRIVE SCREW 04 TO80 PU 10 11 W e VALVE ASSEMBLY 01 T080 PU 11 12 ROTATION DECAL 01 T080 PU 12 13 HEX HEAD CAPSCREW 04 T080 PU 13 14 LOCKW
5. RO 29 x lt ITEMS RECOMMENDED FOR STOCK Review all SAFETY Information in Section A Follow the instructions on all tags labels and decals attached to the pump This pump requires little service due to its rugged minimum maintenance design However if it becomes necessary to inspect or replace the wearing parts follow these instructions which are keyed to the sectional views see Figures 10 and 11 on page 21 amp 23 andthe accompanying parts lists Many service functions may be performed by draining the pump and removing the back cover assembly If major repair is reguired the piping and or power source must be disconnected The following instructions assume complete disassembly is reguired Before attempting to service the pump disconnect or lock out the power source and take precautions to ensure that it will remain inoperative Close all valves in the suction and discharge lines For power source disassembly and repair consult the literature supplied with the power source or contact your local power source representative Before attempting to open or servicethe pump Familiarize yourself with this manual Disconnect or lock out the power source to ensure that the pump will remain inoperative Allow the pump to cool if overheated Check the temperature before opening any covers plates or plugs Closethesuction and discharge valves Ventthe pump slowly and cautiously Drain the pump Use lifting a
6. with a soft cloth soaked in cleaning solvent Inspect the parts for wear or damage as necessary Most cleaning solvents are toxic and flammable Use them only in a well ventilated area free from excessive heat sparks and flame Read and follow all precautions printed on solventcontainers Inspected the shaft for distortion nicks or scratches or for thread damage on the impeller end Dress small nicks and burrs with a fine file or emery cloth Replace the shaft if defective Position the inboard oil seal 7 in the bearing housing bore with the lip positioned as shown in figure 11 page 23 Press the oil seal into the housing until the face is just flush with the machined surface on the housing To prevent damage during removal from the shaft it is recommended that bearings be cleaned and inspected in place It is strongly recommended that the bearings be replaced any time the shaft and bearings are removed NOTE Position the inboard bearing 7 on the shaft with the shielded side toward the impeller end of the shaft Position the outboard bearing 22 on the shaft with the integral retaining ring on the bearing O D toward the drive end of the shaft The bearings may be heated to ease installation An induction heater hot oil bath electric oven or hot plate may be used to heat the bearings Bearings should never be heated with a direct flame or directly on a hot plate NOTE Ifa hotoil bath is used to heat the be
7. Pg Lines Without a Dvpaes ccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees Pg een LL Pg Liquids Temperature and Overheating Pg MENES ETE AA Pg Pump Vacuum Check Pg JEPP JE Pg Cold Weather Preservation Pg 12 BEARING TEMPERATURE CHECK Pg TABLE OF CONTENTS Continued SECTION D TROUBLESHOOTING s cee nnnnnnnnnnnnnnnn nun ann nnn ann van na Pg 18 SECTION E PUMP MAINTENANCE AND REPAIR sss sss Pg 20 13 PERFORMANCE CURVE ca oe CF Fw Pg 20 Pump Model Pg 21 PARTS LB 18 geeiert Pg 22 Repair Rotating Aesembkhy Pg 23 PARTS Eege Pg 24 REPAIR AND MAINTENANCE KITS Pg 25 14 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Pg 26 Back Cover and Wear Plate Hemova Pg 26 Suction Check Valve Hemoval Ynn Y ua Pg 26 Rotating Assembly Removal nnr i i LLun Pg 27 Impeller Removal Pg 28 Seal PEN OA NEE Pg 28 Shaft and Bearing Removal and Disassembly Pg 28 Shaft and Bearing Reassembly and Installation Pg 29 Seal and Installation PQ 31 Impeller Installation LLY eeens eee eeeeeaes Pg 33 Rotating Assembly Installaton es
8. Pg 34 Suction Check Valve Installaton Pg 34 Back Cover Installation Pg 35 15 PRESSURE RELIEF VALVE MAINTENANCE Pg 35 Final Pump Assembly Pg 35 ES ICATION Pg 36 TT ge ins dccccvecdensdeuctenelacavaudeatdecimeninebcneteeeasereainedy Pg 36 TE TEEN Pg 36 LTE LL Pg 36 wn m o o Tm 1 JJ JJ gt lt v eQ UJ co PLEASE NOTE Specifications measurements and other technical data contained in this manual is subject to change without notice INTRODUCTION This Installation Operation and Maintenance manual is designed to help you get the best performance and longest life from your Remko pump This pump is a RT 080 Series semi open impeller self priming centrifugal model with a suction check valve The pump is designed for handling mild industrial corrosives mud or slurries containing large entrained solids The basic material of construction is cast iron with ductile iron impeller and steel wearing parts If there are any guestions regarding the pump or its applications which are not covered in this manual or in other literature accompanying this unit please contact your Remko distributor For information or technical assistance on the power source contact the power source manufacture s local dealer or rep
9. absolutely necessary liquid pressure must be limited to 50 of the maximum permissible operating pressure show on the pump performance curve Pump Vacuum Check With the pump inoperative install a vacuum gauge in the system using pipe dope on the threads Block the suction line and start the pump At operating speed the pump should pull a vacuum of 508mm or more of mercury If it does not check for air leaks in the seal gasket or discharge valve Open the suction line and read the vacuum gauge with the pump primed and at operation speed Shut off the pump The vacuum gauge reading will immediately drop proportionate to static suction lift and should then stabilize If the vacuum reading falls off rapidly after stabilization an air leak exists Before checking for the source of the leak check the point of installation of the vacuum gauge Never halt the flow of liguid suddenly If the liguid being pumped is stopped abruptly damaging shock waves can be transmitted to the pump and piping system Close all connecting valves slowly On engine driven pumps reduce the throttle speed slowly and allow the engine to idle briefly before stopping discharge throttling valve before stopping the pump If the application involves a high discharge head gradually close the CAUTIONN pp 9 9 ge After stopping the pump lock out or disconnect the power source to ensure that the pump will remain inoperative for long periods of time If o
10. and is also eguipped with standard 25mm NPT pipe threads The outlet should be connected to a bleed line which slopes back to the wet well or sump The bleed line must be the same size as the inlet piping or larger If piping is used for the bleed line avoid the use of elbows whenever possible NOTE It is recommended that each Air Release Valve be fitted with an independent bleeder line directed back to the wet well However if multiple airs Release Valves are installed in a system the bleeder lines may be directed to a common manifold pipe Contact your Remko distributor for information about installation of an Automatic Air Release Valve for your specific application The alignment of the pump and its power source is critical for trouble free mechanical operation In either a flexible coupling or V belt driven system the driver and pump must be mounted so that their shafts are aligned with and parallel to each other It is imperative that alignment be checked after the pump and piping are installed and before operation NOTE Check Rotation Section C before alignmentofthe pump When mounted at the Remko factory driver and pump are aligned before shipment Misalignment will occur in transit and handling Pumps must be checking alignment tighten the foundation bolts The pump casing feet and or pedestal feet and the driver mounting bolts should also be tightly secured When checking alignment disconnect the power source to ensure th
11. connection with replacement or repair of defective parts nor shall it apply to a pump upon which repairs or alterations have been made unless authorized by Remko In no event shall Remko be liable for conseguential damages or contingent liabilities arising of the failure of Remko pump or parts there of to operate properly 0 OHN 1800 333 424
12. not recommended Suction inlet at a distance 1 1 2 times the diameter of the suction pipe The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet If two suction lines are installed a single sump the flow paths may interact reducing the efficiency of one or both pumps To avoid this position the suction inlets so thatthey are separated by a distance equal to at least 3 times the diameter of the suction pipe Suction Line Positioning The depth of submergence of the suction line is critical to efficient pump operation Figure 2 below shows recommended minimum submergence vs velocity NOTE The pipe submergence reguired may be reduced by installing a standard pipe increaser fitting atthe end of the suction line The larger opening size will reduce the inletvelocity Calculate the reguired submergence using the following formula based on the increased opening size area or diameter VELOCITY Meters Second VELOCITY M SEC FLOW M MIN x21 22 OR FLOW M7 SEC DIAMETER IN MM AREA IN Mi Figure 2 Recommended Minimum Suction Line Submergence vs Velocity Siphoning Do not terminate the discharge line at a level lower than of the liquid being pumped unless a siphon breaker is used in the line Otherwise a siphoning action causing damage to the pump could resul
13. of impeller shims provided with the seal and screw the impeller onto the shaft until it is seated againstthe seal see Figure 15 below STATIONARY SEAT Z GAS YN e Zen LLII a _ BORE LTE RE PLATE BORE E S Z Hk SX NW SPR i Dy RN 72 JJ OO OG Ny d SHEAR RING FJ EH 7 RING UNSHEARED D Z Lo SHEARED Figure 15 Seal Partially Installed Figure 16 Seal Fully Installed Continue to screw the impeller onto shaft This will press the stationary seat into the seal plate bore NOTE A firm resistance will be felt as the impeller presses the stationery seat into the seal plate bore As the stationery seat becomes fully seated the seal spring compresses and the shaft sleeve will break the nylon shear ring This allows the sleeve to slide down the shaft until seated against the shaft shoulder Continue to screw the impeller onto the shaft until the impeller shims and sleeve are fully seated against the shaft shoulder see Figure 16 above Measure the impeller to seal plate clearance and remove impeller adjusting shims to obtain the proper clearance as described Impeller Installation and Adjustment If nece
14. plug 24 and drain the seal lubricant This will prevent the oil in the seal cavity from escaping when the impeller is loosened Clean and reinstall the seal cavity drain plug Immobilize the impeller by wedging a wood block between the vanes and the pump casing and remove the impeller cap screw and washer 10 and 12 Install a lathe dog on the drive end of the shaft 17 with the V notch positioned over the shaft keyway With the impeller rotation still blocked see Figure 12 below and use a long piece of heavy bar stock to pry against the arm of the lathe dog in a counterclockwise direction when facing the drive end of the shaft Use caution not to damage the shaft or keyway When the impeller breaks loose remove the lathe dog and wood block NOTE Do not remove the impeller until the rotating assembly has been removed from the pump casing Turn Counterclockwise Lathe Dog Arm V Notch j Shaft Keywa Heavy Bar Stock d Impeller Shaft Lathe Dog Set Screw Figure 12 Loosening impeller Figure 10 Page 21 Remove the hardware 13 and 14 securing the rotating assembly to the pump casing Separate the Rotating assembly by pulling straight away from the pump casing NOTE An optional disassembly tool is available from the factory If the tool is used follow the instructions packed with it A similar tool may be assembled using 74 inch pipe schedule 80 steel or malleable iron and a standard tee see Figu
15. the O D ofthe shaft sleeve Slide the rotating portion of the seal consisting of the integral shaft sleeve spring centering washer spring bellows and retainer and rotating element onto the shaft until the seal faces contact Proceed with Impeller Installation and Adjustment Impeller Installation Figure 11 Page 23 Inspect the impeller and replace it if cracked or badly worn Inspect the impeller and shaftthreads for dirt or damage and clean or dress the threads as required The shaft and impeller threads must be completely clean before reinstalling the impeller Even the slightest amount of dirt on the threads can cause the impeller to seize to the shaft making future removal difficult or impossible without damage to the impeller or shaft Install the same thickness of impeller adjusting shims as previously removed Apply Anti S eize or equivalent to the shaft threads and screw the impeller onto the shaft until tight Be sure the seal spring seats sguarely over the shoulder on the back side of the impeller NOTE Atthe slightest sign of binding immediately back the impeller off and check the threads for dirt Do nottry to force the impeller onto the shaft A clearance of 0 64 to 1 02mm between the impeller and the seal plate is recommended for maximum pump efficiency Measure this clearance and add or remove impeller adjusting shims as required NOTE If the rotating assembly has been installed in the pump casing
16. 04 T080 RO 25 26 LOCKWASHER 04 T080 RO 26 27 A O RING SHAFT SLEEVE 01 T080 RO 27 28 A O RING ROTATING ASSEMBLY 01 T080 RO 28 29 IMPELLER ADJUSTING SHIM SET 01 T080 RO 29 Us AVAILABLE IN PORT KIT ONLY AVAILABLE IN BEARING KIT ONLY AVAILABLE AS SET ONLY ITEMS RECOMMENDED FOR STOCK xe OPH AVAILABLE IN SUCTION FLAP VALVE KIT ONLY AVAILABLE IN PUMP GASKET KIT ONLY See page 25 for completed RT 080 Kit Lists COMPLETE RT 080 REPAIR AND MAINTENANCE KITS SPARE PARTS AS KITS x We i SI SF PU GSKT RTO80 Includes T080 PU GSKT Fill Cover Gasket T080 PU 36 Discharge Flange Gasket T080 PU 07 Suction Flange Gasket T080 PU 28 Seal Plate Gasket T080 RO 05 O Ring Back Cover T080 PU 18 O Ring Rotating Assembly T080 RO 28 O Ring Seal Plate T080 RO O Ring Shaft Sleeve T080 RO 27 am SUCTION FLAP VALVE KITS PU SFVK RT080 Includes T080 PU SFVK Check Valve Pin T080 PU 32 Valve Assembly T080 PU 11 PORT KITS PU PTKT RT080 Includes T080 PU PTKT Fill Cover Gasket T080 PU 36 Discharge Flange Gasket T080 PU 07 Suction Flange Gasket T080 PU 28 LIT ee ai RO BRKT RT080 Includes T080 RO BRKT Bearing Cap Gasket T080 RO 21 Seal Plate Gasket T080 RO 05 EZ Inboard Oil Seal TO80 RO 04 Oy Outboard Oil Seal T080 RO 09 Inboard Ball Bearing T080 RO 07 Q Outboard Ball Bearing T080 RO 22 IMPELLER ADJ USTING SHIM SET RO IASS RTO80 Impeller Adjusting Shim Set T080
17. ASHER 04 TO80 PU 14 15 ROTATING ASSEMBLY SCREW SET 04 T080 PU 15 16 xx WEAR PLATE 01 TO80 PU 16 17 CASING DRAIN PLUG 01 T080 PU 17 18 O RING BACK COVER 01 TO80 PU 18 19 HEX NUT 02 T080 PU 19 20 LOCKWASHER 02 T080 PU 20 21 INSPECTION COVER BOLT 02 T080 PU 21 22 STUD 02 T080 PU 22 23 BACK COVER PLATE ASSEMBLY 01 T080 PU 23 24 WARNING PLATE 01 T080 PU 24 25 DRIVE SCREW 04 T080 PU 25 26 CAUTION DECAL 01 TO80 PU 26 27 PRESSURE RELIEF VALVE 01 T080 PU 27 28 6 A SUCTION FLANGE GASKET 01 T080 PU 28 29 HEX HEAD CAPSCREW 04 T080 PU 29 30 LOCKWASHER 04 T080 PU 30 31 PIPE PLUG 01 T080 PU 31 32 W e CHECK VALVE PIN 01 T080 PU 32 33 PIPE PLUG 01 T080 PU 33 34 CLAMP BAR 01 T080 PU 34 EZ 35 MACHINE BOLT 02 T080 PU 35 36 A FILL COVER GASKET 01 TO80 PU 36 JJ 37 CLAMP BAR SCREW 01 T080 PU 37 38 FILL COVER PLATE 01 T080 PU 38 4 39 WARNING PLATE 01 T080 PU 39 40 DRIVE SCREW 02 T080 PU 40 41 BACK COVER HANDLE 02 T080 PU 41 42 HEX HEAD CAPSCREW 04 T080 PU 42 43 LOCKWASHER 04 T080 PU 43 xe sep AVAILABLE IN SUCTION FLAP VALVE KIT ONLY AVAILABLE IN PUMP GASKET KIT ONLY AVAILABLE IN PORT KIT ONLY AVAILABLE IN BEARING KIT ONLY AVAILABLE AS SET ONLY ITEMS RECOMMENDED FOR STOCK See page 25 for completed RT 080 Kit Lists SECTION DRAWING DRIVE END VIEW
18. Cartridge Seal Assembly CAUTI This seal is not designed for operation at temperatures above 71 C Do notuse athigher operating temperatures If the seal plate was removed install the seal plate gasket 5 Position the seal plate over the shaft and secure it to the bearing housing with the hardware 25 and 26 To prevent damaging the shaft sleeve O ring on the shaft threads stretch the O ring over a piece of tubing 32mm x 38mm x 51mm To ease installation of the seal lubricate the shaft sleeve O ring and the external stationary seat O ring with a very small amount of light lubricating oil See Figure 14 page 30 for seal part identification Slide the tube over the shaft threads and then slide the O ring off the end onto the shaft Remove the tube and continue to slide the O ring down the shaft until it seats against the shaft shoulder When installing a new cartridge seal assembly remove the seal from the container and remove the Mylar storage tabs from between the seal faces between the seal faces These storage tabs must be removed before installing the seal New cartridge seal assemblies are eguipped with Mylar storage tabs CAUTIONN Lubricate the external stationary seat O ring with light oil Slide the seal assembly onto the shaft until the external stationery seat O ring engages the bore in the seal plate Clean and inspectthe impeller as described in Impeller Installation and Adjustment Install the full set
19. Final Pump Assembly Figure 10 Page 21 Install the shaft Key 16 Figure 11 page 23 and reconnect the power source Be sure to install any guards used over the rotating members rotating parts Exposed rotating parts can catch clothing fingers or tools causing severe injury to personnel Do not operate the pump without the guards in place over the DANGE Install the suction and discharge lines and open all valves Make certain that all piping connections are tight properly supported and secure Be sure the pump and power source have been properly lubricated see LUBRICATION Remove the fill cover assembly and fill the pump casing with clean liguid Reinstall the fill cover and tighten it Refer to OPERATION Section C before putting the pump back into service SealAssembly Figure 11 Page 23 Before starting the pump remove the vented plug 8 and fill the seal cavity with approximately 0 6 litres of SAE No 30 non detergent oil or to a level just below the tapped vented plug hole Clean and reinstall the vented plug Maintain the oil at this level Bearings Figure 11 Page 23 The bearing housing was fully lubricated when shipped from the factory Check the oil level regularly through the sight gauge When lubrication is required add SAE No 30 non detergent oil through the hole for the air vent 11 Do not over lubricate Over lubrication can cause the bearings to overheat resulting in premature bearing fai
20. Note the direction of rotation indicated on the pump Check that the pump shaft rotates counterclockwise when facing the back cover plate assembly impeller end of the pump pump body and on the accompanying decal Refer to ROTATION in OPERATION Section C Only operate this pump in the direction indicate by the arrow on the CAUTIO a Check levels and lubricate as necessary Refer to LUBRICATION in the MAINTENANCE AND REPAIR section of this manual and perform duties as instructed b Ifthe pump and power source have been stored for more than 12 months some of the components or lubricants may have exceeded their maximum shelf life These must be inspected or replaced to ensure maximum pump service c If the maximum shelf life has been exceeded or if anything appears to be abnormal contact your Remko distributor or the factory to determine the repair or updating policy Do not put the pump into service until appropriate action has been taken Lifting Use lifting equipment with a capacity of at least 900kg This pump weighs approximately 190kg not including the weight of accessories and base Customer installed equipment such as suction and discharge piping must be removed before attempting to lift gt NE chains used to lift and move the unit is improperly wrapped around the pump The pump assembly can be seriously damaged if the cables or CAUTIONN Mounting Locate the pump in an accessible place as clos
21. OPERATORS MANUAL Installation Operation Maintenance and Parts List TABLE OF CONTENTS INTRODUCTION I PRY YDYN YDA A YDW DWN Pg SECTION A SAFETY U U U u u u u Pg SECTION B INSTALLATION U U u ARAN AN Pg Pump WR VE EE Pg 1 PREINSTALLATION INSPECTION Pg 2 POSITIONING PUPP arsen Pg EG EEE Pg MOUNINO EEE rea a a Pg Clearance EEE Pg 3 SUCTION AND DISCHARGE DIDING Pg E a Pg Line Configuration Pg Connections to Pump Pg NS SS EEE qaa Bs Pg 4 SUCTION LINES see idy SR RF FO RR yb Pg FIS TR PEN RR NN RYN FYN Pg STANGS see Pg 521 e EE Pg Suction Lines in Sumps Po Suction Lines Posittoninmg P 5 DISCHARGE LINES cud NY NA MORON Pg leien ie DE Pg Ve Pg se SN YF NN YF HEH FF EE RW TU NN FYR Pg 6 AUTOMATIC AIR RELEASE VAIVE Pg Theory of Operation Pg Air Release Valve Installation Pg LE me EE Pg Coupled Drivers Pg EST LL Pg SECTION i Ie TTT Pg AMAU ONS EE Pg tie EEN Pg Bota LL Pg Ti ll Pg Lines Er ME
22. adjust an equal of screw from each rotating assembly screw set until the impeller scrapes against the wear plate when the shaft is turned After the impeller scrapes adjust approximately 0 4mm of clearance with the screw set NOTE An alternate method of adjusting this clearance is to reach through the suction port with a feeler gauge and measure the gap Adjust rotating assembly screw accordingly Suction Check Valve Installation Figure 10 Page 21 Inspect the check valve assembly 11 and replace it if badly worn NOTE The check valve assembly must be replaced as a complete unit Individual parts are notsold separately Reach through the back cover opening with the check valve 11 and position the check valve adaptor in the mounting slot in the suction flange 3 Align the adaptor with the flange hole and secure the assembly with the check valve pin 32 NOTE Ifthe suction or discharge flanges were removed replace the respective gaskets apply Loctite No 3 Aviation Gasket Sealant or equivalent compound to the mating surfaces and secure them to the pump casing with the attaching hardware Back Cover Installation Figure 10 Page 21 If the wear plate 16 was removed for replacement carefully centre it on the back cover and secure it with the hardware 19 and 20 The wear plate must be concentric to prevent binding when the back cover is installed Replace the back cover O ring 18 and lubricate it with a g
23. arge entrained solids Do not attempt to pump volatile corrosive or flammable materials which may damage the pump or endanger personnel as resultof pump failure After the pump has been positioned make certain thatthe pump and all piping connections are tight properly supported and secure before operation Do not operate the pump without the guards in place over the rotating parts Exposed rotating parts can catch clothing fingers ortools causing severe injury to personnel Do notremove plates covers gauges pipe plugs or fittings from an overheated pump Vapour pressure within the pump can cause parts being disengaged to be ejected with great force Allow the pump to cool before servicing O Do notoperate the pump againsta closed discharge valve for long periods of time If operated against a closed discharge valve pump components will deteriorate and the liquid could come to a boil pressure and cause the pump casing to rupture or explode Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment Suction and discharge hoses and piping must be removed before lifting SECTION B INSTALLATION Review all SAFETY information in Section A Since pump installations are seldom identical this section offers only general recommendations and practices reguired to inspect position and arrange the pump and piping Most of the information perta
24. arings both the oil and the container must be absolutely clean Ifthe oil has been previously used itmust be thoroughly filtered Heat the bearings to a uniform temperature no higher than 120 C and slide the bearings onto the shaft one at a time until they are fully seated This should be done guickly in one continuous motion to prevent the bearings from cooling and sticking onthe shaft After the bearings have been installed and allowed to cool check to ensure that they have not moved away from the shaft shoulders in shrinking If movement has occurred use a suitable sized sleeve and a press to reposition the bearings against the shaft shoulders If heating the bearings is not practical use a suitable sized sleeve and an arbor or hydraulic press to install the bearings on the shaft When installing the bearings onto the shaft never press or hit against the outer race ball orballcage Press only onthe inner race Secure the outboard bearing on the shaft with the bearing retaining ring 18 Slide the shaft and assembled bearings into the bearing housing until the retaining ring on the outboard bearing seats against the bearing housing When installing the shaft and bearings into the bearing bore push againstthe outer race Neverhit the balls or ball cage DN Press the outboard oil seal 9 into the bearing cap 15 with the lip positioned as shown in figure 11 page 23 Replace the bearing cap gasket 21 an
25. at the pump will remain inoperative Adjusting the alignment in one direction may alter the alignment in another direction Check each procedure after altering alignment Coupled Drives When using couplings the axis of the power source must be aligned the axis of the pump shaft in both the horizontal and vertical planes Most couplings require a specific gap or clearance between the driving and the driven shafts Refer to the coupling manufacturer s service literature Align spider insert type couplings by using calipers to measure the dimensions on the circumference of the outer ends of the coupling hub every 90 degrees The coupling is in alignment when the hub ends are the same distance apart at all points see Figure 6 page 13 Figure 7 Aligning Non Spider Figure 6 Aligning Spider Type Couplings Type Couplings Align non spider type couplings by using a feeler gauge or taper gauge between the couplings halves every 90 degrees The coupling is in alignment when the hubs are the same distance apart at all points see Figure7 above Check parallel adjustment by laying a straightedge across both coupling rims at the top bottom and side When the straightedge rests evenly on both halves of the coupling the coupling is in horizontal parallel alignment If the coupling is misaligned use a feeler gauge between the coupling and the straightedge to measure the amount of m
26. ble liguids which may damage the pump or endanger personnel as a resultof pump failure Pump speed and operating conditions must be within the performance range shown on page 20 figure 9 Install the pump and piping as describe in INSTALLATION Make sure that the piping connections are tight and that the pump is securely mounted Check that the pump is properly lubricated see LUBRICATION in MAINTENANCE AND REPAIR This pump is self priming but the pump should never be operated unless there is liguid in the pump casing Never operate this pump unless there is liguid in the pump casing The pump will not prime when dry Extend operation of a dry pump will destroy the seal assembly Add liguid to the pump casing when 1 Thepump is being put into service for the firsttime 2 Thepump has not been used for a considerable length of time 3 The liquid in the pump casing has evaporated Once the pump casing has been filled the pump will prime and reprime as necessary After filling the pump casing reinstall and tighten the fill plug Do not attemptto operate the pump unless all connecting piping is securely installed Otherwise liquid in the pump forced out under pressure could cause injury to personnel To fill the pump remove the pump casing fill cover or fill plug in the top of the casing and add clean liquid until the casing is filled Replace the fill cover or fill plug before operating the pump D Consult t
27. d secure the bearing cap with the hardware 13 and 14 Be careful not to damage the oil seal lip on the shaft keyway Lubricate the bearing housing as indicated in LUBRICATION Seal Installation Figures 11 pg 23 14 below 15 pg 31and 16 pg 31 well ventilated area free from excessive heat sparks and flame Read and follow all precautions printed on solvent containers Most cleaning solvents are toxic and flammable Use them only ina WAR NING Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent Inspect the stationary seat bore in the seal plate for dirt nicks and burrs and remove any that exist The stationary seat bore mustbe completely clean before installing the seal from the pump Wear patters on the finished faces cannot be realigned Anew seal assembly should be installed any time the old seal is removed CAUTION 7 during reassembly Reusing an old seal could result in premature failure RETAINER SPRING SEAL PLATE RIN IMPELLER a SS SLEEVE IMPELLER O RING SHIMS IMPELLER SHAFT ROTATING STATIONARY INTEGRAL BELLOWS ELEMENT ELEMENT SHAFT SLEEVE d 4 RER Q SHEAR v RING SHEARED DRIVE BAND SPRING f CENTERING STATIONARY WASHER SEAT Figure 14
28. e as practical to the liquid being pumped Level mounting is essential for proper operation The pump may have to be supported or shimmed to provide for level operation or to eliminate vibration Clearance When positioning the pump ensure clearances of 500 mm at both the back cover and rotating assembly allowing easy access to the pump interior Pump performance is adversely affected by increase suction lift discharge elevation And friction losses See the performance curve and operating range shown on Page 20 to be sure your overall application allows pump to operate within the safe operation range Figure 9 Materials Either pipe or hose maybe used for suction and discharge lines however the materials must be compatible with liguid being pumped If hose is used in suction lines it must be the rigid wall reinforced type to prevent collapse under suction Using piping couplings in suction lines is notrecommended Line Configuration Keep suction and discharge lines as straight as possible to minimize friction losses Make minimum use of elbows and fittings which substantially increase friction loss If elbows are necessary use the long radius type to minimize friction loss Connections to Pump Before tightening a connecting flange align it exactly with the pump port Never pull a pipe line into place by tightening the flange bolts and or couplings Lines near the pump must be independently supported to avoid strain
29. e bearings are at the point of failing to operate properly Make certain that the bearing lubricant is of the proper viscosity and at the correct level see LUBRICATION in MAINTENANCE AND REPAIR Bearing overheating can also be caused by shaft misalignment and or excessive vibration When pumps are first started the bearings may seem to run at temperatures above normal Continued operation should bring the temperatures down to normal levels SECTION D TROUBLESHOOTING Review all SAFETY information in Section A Before attempting to open or service the pump WARNING Familiarize yourself with this manual Lock out or disconnect the power source to ensure that the pump will remain inoperative Allow the pump to cool if overheated Check the temperature before opening any covers plates or plugs Closethesuction and discharge valves Ventthe pump slowly and cautiously Drainthepump TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP FAILS Not enough liquid in casing Add liguid to casing See PRIMING TO PRIME Suction check valve contaminated or Clean or replace check valve damaged Air leak in suction line Correct leak Lining of suction hose collapsed Replace suction hose Leaking or worn seal or pump gasket Check pump vacuum Replace leaking or worn seal or gasket Suction lift or discharge head too high Check piping installation and install bypass line if needed See INSTALLATION St
30. eck valve or foot valve clogged or binding Correct leak Replace suction hose Check pump vacuum Replace leaking or worn seal or gasket Check strainer and clean if necessary Check installation and correct sub mergence as needed Replace worn or damaged parts Check that impeller is properly centred and rotates Free impeller of debris Check driver output check belts or couplings for slippage Install bypass line Measure lift with vacuum gauge Reduce lift and or friction losses in suction line Check driver output check that sheaves or motor rpm are correctly sized Adjust discharge valve Dilute if possible Disassemble pump and check bearing s Dilute if possible Open discharge valve fully to increase flow rate and run power source at maximum governed speed Clean valve SECTION E PUMP MAINTENANCE AND REPAIR MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE 13 PERFORMANCE CURVE STANDARD PERFORMANCE FOR PUMP MODEL RT 0 0 m 11 2 KW n Operating Range 2150 RPM a 40 30 35 40 45 48 50 Se 2050 36 E 1950 ki 32 mM Mine le EN Sea ai a i TE SS o gr See sa 00 00 02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32 ve EE iz 16 1350 y y G ae z 1250 EET ay ie lt d 12 saa 45 osa EE l 00 10 20 30 40 50 60 70 80 90 100 110 FLOW RATE Remko RT 080
31. ecrease tension on the spring Contact your Remko distributor for information aboutan Automatic Air Release Valve for your specific application Air Release Valve installation The Automatic Air Release Valve must be independently mounted in a horizontal position and connected to the discharge line of the self priming centrifugal pump see Figure 5 below NOTE If the Air Release Valve is to be installed on a staged pump application contactthe factory for specific installation instructions COVER cLEAN OUT _ ll Im J senare PIPE INSTALL AIR RELEASE VALVE IN HORIZONTAL POSITION 90 LONG m RADIUS d ELBOW a SUPPORT i __DISCHARGE PIPE BRACKET ae BLEED LINE CENTRIFUGAL FURNISHED PUMP BELOW LIQUID i lm LEVEL SURFACE pr r DRAIN LINE WET WELL OR SUMP Figure 5 Typical Automatic Air Release Valve Installation The valve inlet must be installed between the pump discharge port and the non pressurized side of the discharge check valve The valve inlet is it at the large end of the valve body and is provided with standard 25mm NPT pipe threads The valve outlet is located at the opposite end of the valve
32. enerous amount of No 2 grease Clean any scale or debris from the contacting surfaces in the pump casing that might interfere or prevent a good seal with the back cover Slide the back cover assembly into the pump casing Be sure the wear plate does not bind against the impeller NOTE To ease future disassembly apply a film of grease or Anti Seize on the back cover shoulder or any surface which contacts the pump casing This action will reduce rustand scale build up Secure the back cover assembly by tightening the hand nuts 21 evenly Do not over tighten the hand nuts they should be just tight enough to ensure a good seal at the back cover shoulder Be sure the wear plate does not bind againstthe casing Figure 10 Page 21 The back cover is eguipped with a pressure relief valve 27 to provide additional safety for the pump and operator refer to Liguid Temperature And Overheating in OPERATION It is recommended that the pressure relief valve assembly be replaced at each overhaul or any time the pump overheats and activates the valve Never replace this valve with a substitute which has not been specified or provided by Remko Periodically the valve should be removed for inspection and cleaning When reinstalling the relief valve apply Loctite Pipe Sealant With Teflon No 592 or eguivalent compound on the relief valve threads Position the valve as shown in Figure 10 page 21 with the discharge port pointing down
33. he level pump In some installations this bypass line may be terminated with a 1800 2400mm length of 32mm ID Smooth bore hose air and liquid vented during the priming process will then agitate the hose and break up any solids grease or other substances likely to cause clogging being drawn into the pump suction inlet A bypass line thatis returned to a wet well must be secured against CAUTION yp g Itis also recommended that pipe unions be installed at each 90 elbow in a bypass line to ease disassembly and maintenance In high discharge head applications more than 9 metres an excessive amount of liquid may be bypassed and forced back to the wet well under the full working pressure of the pump this will reduce overall pumping efficiency Therefore it is recommended that an Automatic Air Release Valve be installed in the bypass line Automatic Air Release Valves are reliable and reguire minimum maintenance See AUTOMATIC AIR RELEASE VALVE in this section for installation and theory of operation of the Automatic Air Release Valve Contact your Remko distributor for selection of an Automatic Air Release Valve to fit your application If the installation involves a flooded suction such as below ground lift station A pipe union and manual shut off valve may be installed in the bleed line to allow service of the valve without shutting down the station and to eliminate the possibility of flooding If a manual shut off valve is in
34. he operations manual furnished with the power source Rotation The correct direction of pump rotation is counterclockwise when facing the impeller The pump could be damaged and performance adversely affected by incorrect rotation If pump performance is not within the specified limits see the curve on page 20 checkthe direction of power source rotation before further troubleshooting figure 9 If an electric motor is used to drive the pump remove V belts couplings or otherwise disconnectthe pump from the motor before checking motor rotation Operate the motor independently while observing the direction ofthe motor shaft or cooling fan If rotation is incorrect on a three phase motor have a qualified electrician interchange any of the phase wires to change direction If rotation is incorrect on a single phase motor consult the literature supplied with the motor for specific instructions Lines with a Bypass If an Automatic Air Release Valve has been installed the valve will automatically open to allow the pump to prime and automatically close after priming is complete see INSTALLATION for Air Release Valve operation Lines without a Bypass Open all valves in the discharge line and startthe power source Priming is indicated by a positive reading on the discharge pressure gauge or by a guieter operation The pump may not prime immediately because the suction line must first fill with liquid Ifthe pump fails to prime within five m
35. ins to a standard static liftapplication where the pumpis positioned above the level of liquid to be pumped If installed in a flooded suction application where the liquid is supplied to the pump under pressure some of the information such as mounting line configuration and priming must be tailored to the specific application Since the pressure supplied to the pump is critical to performance and safety be sure to limit incoming pressure to 50 of the maximum permissible operating pressure as shown on the pump performance curve For further assistance contact your Remko distributor Pump Dimensions See Figure 1 below for the approximate physical dimensions of this pump OUTLINE DRAWING DIMENSIONS MILLIMETRES 80MM ANSI 150 80MM ANSI 150 i Figure 1 Pump Model RT 080 The pump assembly was inspected and tested before from the factory Before installation inspect the pump for damage which may have occurred during shipment Check as follows a Inspect the pump for cracks dents damaged threads and other obvious damage b Check for and tighten loose attaching hardware Since gaskets tend to shrink after drying check for loose hardware at mating surfaces c Carefully read all warnings and cautions contained in this manual or affixed to the pump and perform all duties indicated
36. inutes stop it and check the suction line for leaks After the pump has been primed partially close the discharge line throttling valve in order to fill the line slowly and guard against excessive shock pressure which could damage pipe ends gaskets sprinkler heads and any other fixtures connected to the line When the discharge line is completely filled adjust the throttling valve to the required flow rate JJ Do not operate the pump against a closed discharge throttling valve e WARNING for long periods of time If operated against a closed discharge throttling valve pump components will deteriorate and the liguid could come to a boil build pressure and cause the pump casing to rupture or explode Leakage No leakage should be visible at pump mating surfaces or at pump connections or fittings Keep all line connections and fittings tight to maintain maximum pump efficiency Liguid Temperature and Overheating The maximum liquid temperature for this pump is 71 C Do not apply it at a higher operating temperature Overheating can occur if operated with the valves in the suction or discharge lines closed Operating against closed valves could bring the liguid to a boil build pressure and cause the pump to rupture or explode If overheating occurs stop the pump and allow itto cool before servicing it Refillthe pump casing with cool liquid Allow an over heated pump to cool before servicing Do not remove plates co
37. isalignment V BeltDrives When using V belt drives the power source and the pump must be parallel Use a straightedge along the sides of the pulleys to ensure that the pulleys are properly aligned see Figure 8 below In drive systems using two pr more belts make certain thatthe belts are a matched set unmatched sets will cause accelerated belt wear MISALIGNED SHAFTS MISALIGNED SHAFTS ALIGNED SHAFTS NOT PARALLEL NOT IN LINE PARALLEL AND SHEAVES IN LINE Figure 8 Alignment of V Belt Driven Pumps Tighten the belts in accordance with the belt manufacturer s instructions If the belts are too loose they will slip if the belts are too tight there will be excessive power loss and possible bearing failure Select pulleys that will match the proper speed ratio over speeding the pump may damage both pump and power source parts Exposed rotating parts can catch clothing fingers or tools Do notoperate the pump withoutthe guard in place over the rotating DANGE l ro causing severe injury to personnel O SECTION C OPERATION Review all SAFETY information in Section A Follow instructions on all tags labels and decals attached to the pump This pump is designed to handle mild industrial corrosives mud or slurries containing large entrained solids Do not attempt to pump volatile corrosive or flamma
38. lure NOTE The white reflector in the sight gauge must be positioned horizontally to provide proper drainage Under normal conditions drain the bearing housing once each year and refill with approximately 0 8 litre clean oil Change the oil more frequently if the pump is operated continuously or installed in an environmentwith rapid temperature change or moisture condensation This is especially important in areas where variable and cold temperatures are common Monitor the condition of the bearing lubricant regularly for evidence of rust CAUTIONN For cold weather operation consult the factory or a lubricant supplier for the recommended grade of oil PowerSource Z Consult the literature supplied with the power source or contact your local power source representative GTI SECTION F WARRANTY WARRANTY TERMS amp CONDITIONS Pumping units manufactured by Remko are guaranteed to be free from defects in material and workmanship for one year from date of shipment from factory The obligation under this Warranty statutory or otherwise is limited to replacementor repairatfactory or ata point designated by Remko of such as part as shall appear to us upon inspection at such point to have been defective in material orworkmanship This Warranty does not obligate Remko to bear the cost of labour or transportation charges in
39. n the seal plate on a flat surface with the impeller side down Use a wooden dowel or other suitable tool to press on the back side ofthe stationary seatuntil the seat O rings and stationary element can be removed Remove the shaft sleeve O ring If no further disassembly is required refer to seal installation Shaftand Bearing Removal and Disassembly Figure 11 Page 23 When the pump is properly operated and maintenance the bearing housing should not reguire disassembly Disassemble the shaft and bearings only when there is evidence of wear or damage Shaft and bearing disassembly in the field is not recommended These operations should be performed only in a properly eguipped shop by gualified personnel Remove the bearing housing drain plug 23 and drain the lubricant Clean and reinstall the drain plug Disengage the hardware 13 and 14 and slide the bearing cap 15 and oil seal 9 off the shaft Remove the bearing cap gasket 21 and press the oil seal from the bearing cap Place a block of wood against the impeller end of the shaft and tap the shaft and assembled bearings 7 and 22 from the bearing housing sie removing the shaft and bearings clean and inspect the bearings in place as follows To prevent damage during removal from the shaft it is recommended that bearings be cleaned and inspected in place It is strongly recommended that the bearings be replaced any time the shaftand bearings are removed
40. nd moving equipment in good repair and with adeguate capacity to preventinjuries to personnel or damage to eguipment Back Coverand Wear Plate Removal Figure 10 Page 21 The wear plate 16 is easily accessible and may be serviced by removing the back cover assembly 23 Before attempting to service the pump remove the pump casing drain plug 17 and drain the pump Clean and reinstall the drain plug D Remove the hand nuts 21 and pull the back cover and assembled wear plate from the pump casing 1 Inspected the wear plate and replace it if badly scored or worn To remove the wear plate disengage the hardware 19 and 20 Inspect the back cover O ring 18 and replace it if damaged or worn Suction Check Valve Removal Figure 10 Page 21 If the check valve assembly 11 is to be serviced remove the check valve pin 32 reach through the back cover opening and pull the complete assembly from the suction flange 3 NOTE Further disassembly of the check valve is not reguired since it must be replaced as a complete unit Individual parts are notsold separately Rotating Assembly Removal Figure 11 Page 23 The rotating assembly may be serviced without disconnecting the suction or discharge piping however the power source must remove to provide clearance The impeller 1 should be loosened while the rotating assembly is still secured to the pump casing Before loosening the impeller remove the seal cavity drain
41. on the pump which could cause excessive vibration decrease bearing life and increased shaft and seal wear If hose type lines are used they should have adequate support to secure them when filled with liguid and under pressure Gauges Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges If these gauges are desired for pumps that are not tapped drill and tap the suction and discharge lines not less than 500mm from the suction and discharge ports and install the lines Installation closer to the pump may result in erratic readings To avoid air pockets which could affect pump priming the suction line must be as short and direct as possible When operation involves a suction lift the line must always slope upward to the pump from the source of the liquid being pumped if the line slopes down to the pump at any point along the suction run air pockets will be created Fittings Suction lines should be the same size as the pump inlet If reducers are used in suction lines they should be the eccentric type and should be installed with the flat part of the reducers uppermost to avoid creating air pockets Valves are not normally used in suction lines but if a valve is used install it with the horizontal to avoid air pockets Strainers If a strainer is furnished with the pump be certain to use it any spherical solids which pass through a strainer furnished with the pump will also pass through the p
42. perated against a closed discharge Do not operate the pump against a closed discharge throttling valve WARNING I throttling valve pump components will deteriorate and the liquid could come to a boil build pressure and cause the pump casing to rupture or explode Cold Weather Preservation In below freezing conditions drain the pump to prevent damage from freezing Also clean out any solids by flushing with a hose Operate the pump for approximately one minute this will remove any remaining liguid that could freeze the pump rotating parts If the pump will be idle for more than a few hours or if it has been pumping liguids containing a large amount of solids drain the pump and flush it thoroughly with clean water To prevent large solids from clogging the drain port and preventing the pump from completely draining insert a rod or stiff wire in the drain port and agitate the liguid during the draining process Clean out any remaining solids by flushing with a hose Bearings normally run at higher than ambient temperatures because of heat generated by friction Temperatures up to 71 C are considered normal for bearings and they can operate safely to at least 82 C Checking bearing temperatures by hand is inaccurate Bearing temperatures can be measured accurately by placing a contact type thermometer against the housing Record this temperature for future reference A sudden increase in bearing temperature is a warning that th
43. rainer clogged Check strainer and clean if necessary EXCESSIVE Cavitation in pump Reduce suction lift and or friction losses NOISE in suction line Record vacuum and pressure gauge readings and consult local representative or factory Pumping entrained air Locate and eliminate source of air bubble Pump or drive not securely mounted Secure mounting hardware Impeller clogged or damaged Clean out debris replace damaged parts BEARINGS Bearing temperature is high but within Check bearing temperature regularly to RUN TOO HOT limits monitor any increase Low or incorrect lubricant Check for proper type and level of lubricant Suction and discharge lines not properly Check piping installation for proper supported support Drive misaligned Align drive properly TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE PUMP REOUIRES TOO MUCH POWER PUMP CLOGS FREOUENTLY Air leak in suction line Lining of suction hose collapsed Leaking or worn seal or pump gasket Strainer clogged Suction intake not submerged at proper level or sump too small Impeller or other wearing parts worn or damaged Impeller clogged Pump speed too slow Discharge head too high Suction lift too high Pump speed too high Discharge head too low Liguid solution too thick Bearing s frozen Liguid solution too thick Discharge flow too slow Suction ch
44. re 13 Page 27 All threads are 12inch NPT Do notpre assemble the tool Ve APPROX 152MM LONG PG APPROX 356 MM LONG Figure 13 Rotating Assembly Tool To install the tool remove the air vent 8 Figure 11 Page 23 from the bearing housing and screw the longest length of pipe into the vent whole until fully engaged Install the tee and screw the handles into the tee Use caution when lifting the rotating assembly to avoid injury to personnel or damage to the assembly Remove the bearing housing and seal plate O rings 9 and 4 Impeller Removal Figure 11 Page 23 With the rotating assembly removed from the pump casing unscrew the impeller from the shaft Use caution when unscrewing the impeller tension on the shaft seal spring will be released as the impeller is removed Inspect the impeller and replace if cracked or badly worn Remove the impeller adjusting shims tie and tag the shims or measure and record their thickness for ease of reassembly Seal Removal Figure 11 Page 23 Slide the integral shaft sleeve and rotating portion of the seal off the shaft as unit Use a pair of stiff wires with hooked ends to remove the stationary element and seat An alternative method of removing the stationary seal components is to remove the hardware 25 and 26 and separate the seal plate 3 and gasket 5 from the bearing housing 6 Positio
45. resentative The following are used to alert maintenance personnel to procedures which reguire special attention to those which could damage equipment and to those which could be dangerous to personnel Immediate hazards which WILL result in severe personal injury or death These instructions describe the procedure reguired and the injury which will resultfrom failure to follow procedure Hazards or unsafe practices which COULD result in minor personal injury or product or property damage These instructions describe the reguirements and the possible damage which could result from failure to follow the procedure NOTE Instructions to aid in installation operation and maintenance or which clarify a procedure SECTION A SAFETY These warnings apply to RT series basic pumps Remko has no control over or particular Knowledge of the power source which will be used Refer to the manual accompanying the power source before attempting to begin operation Before attempting to open or service the pump 1 Familiarize yourself with this manual Disconnect or lock out the power source to ensure that the pump will remain inoperative Allow the pump to cool if overheated Check the temperature before opening any covers plates or plugs Close the suction and discharge valves Vent the pump slowly and cautiously Drain the pump This pump is designed to handle mild industrial corrosives mud or slurries containing l
46. ssary to reuse an old Seal in an emergency carefully separate the rotating and stationary seal faces from the bellows retainer and stationary seat A new seal assembly should be installed any time the old seal is removed from the pump Reusing an old seal could result in premature failure Handle the seal parts with extreme care to prevent damage Be careful not to contaminate precision finished faces even fingerprints on the faces with a non oil based solvent and a clean lint free tissue Wipe lightly in a concentric pattern to avoid scratching the faces Carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly Do not attempt to separate the rotating portion of the seal from the shaft sleeve when reusing an old seal The rubber bellows will adhere to the sleeve during use and attempting to separate them could damage the bellows Inspect the seal components for wear scoring grooves and other damage that might cause leakage Inspect the integral shaft sleeve for nicks or cuts on either end If any components are worn or the sleeve is damaged replace the complete seal never mix old and new seal parts Install the stationary seal element in the stationary seat Press this stationary subassembly into the seal plate bore until it seats squarely against the bore shoulder A push tube made from a piece of plastic pipe would aid this installation The I D of the pipe should be slightly larger than
47. stalled anywhere in the air release piping it must be a full opening ball type valve to prevent plugging by solids If a manual shut off valve is installed in a bypass line it must not be left closed during operation closed manual shut off valve may cause a pump which has lost prime to continue to operate without reaching prime causing dangerous overheating and possible explosive rupture of the pump casing Personnel could be severely injured Allow an over heated pump to cool before servicing Do not remove plates covers gauges or fittings from an overheated pump Liguid within the pump can reach boiling temperatures and vapour pressure within the pump can cause parts being disengaged to be ejected with great force After the pump cools drain the liguid from the pump by removing the casing drain plug Use caution when removing the plug to preventinjury to personnel from hotliguid When properly installed and correctly adjusted to the specific hydraulic operating conditions of the application the Automatic Air Release Valve will permit air to escape through the bypass line and then close automatically when the pump is fully primed and pumping at full capacity Theory of Operation Figures 3 and 4 below show a cross sectional view of the Automatic Air Release Valve and a corresponding description of operation
48. t VALVES If a throttling valve is desired in the discharge line use a valve as large as the largest pipe to minimize friction losses Never install a throttling valve in a suction line With high discharge heads it is recommended that a throttling valve and a system check valve be installed in the discharge line to protect the pump from excessive shock pressure and reverse rotation when itis stopped If the application involves a high discharge head gradually close the CAUTIONN 5 Se discharge throttling valve before stopping the pump Bypass Lines Self priming pumps are not air compressors During the priming cycle air from the suction line must be vented to atmosphere on the discharge side If the discharge line is open this air a check valve has been installed in the discharge line the discharge side of the pump must be opened to atmospheric pressure through a bypass line installed between the pump discharge an the check valve A self priming centrifugal pump will not prime if there is sufficient static liquid head to hold the discharge check valve closed NOTE The bypass line should be sized so that it does not affect pump discharge capacity however the bypass line should be at least 25mm in diameter to minimize the chance of plugging In low discharge head applications less than 9 meters it is recommended that the bypass line be run back to the wet well and locate 150mm below the water level or cut off point of t
49. this clearance may be measured by reaching through the priming port with a feeler gauge NOTE Proceed with Rotating Assembly Installation before installing the impeller cap screw and washer 10 and 12 The rotating assembly must be installed in the pump casing in order to torque the impeller cap screw After the rotating assembly is installed in the pump casing coat the threads of the impeller cap screw 10 with Threadlocker or equivalent compound and install the impeller washer 12 and cap screw torque the cap screw to 12 4 m kg Rotating Assembly Installation Figure 11 Page 23 NOTE If the pump has been completely disassembled it is recommended that the suction check valve and back cover assembly be reinstalled at this point The back cover assembly mustbe in place to adjust the impeller face clearance Install the bearing housing and seal plate O rings 27 and 28 and lubricate them with light grease Ease the rotating assembly into the pump casing using the installation tool Be careful not to damage the O rings Install the four screw sets of rotating assembly adjusting screw 15 using the same thickness as previously removed Secure the rotating assembly to the pump casing with the hardware 13 and 14 Do not fully tighten the cap screw until the back cover has been set A clearance of 0 25 to 0 51mm between the impeller and the wear plate is also recommended for maximum pump efficiency This clearance can be obtained by
50. ump itself If a strainer is not furnished with the pump but is installed by the pump user make certain that the total area of the openings in the strainer is at least three or four times the cross section of the suction line and that the openings will not permit passage of solids larger than the solids handling capability of the pump This pump is designed to handle up to 63 mm diameter spherical solids Sealing Since even a slight leak will affect priming head and capacity especially when operating with a high suction lift all connections in the suction line should be sealed with pipe dope to ensure an airtight seal Follow the sealant manufacturer s recommendations when selecting and applying the pipe dope The pipe dope should be compatible with the liguid being pumped Suction Lines in Sumps If a single suction line is installed in a sump it should be positioned away from the wall of the sump ata distance equal to 1 2times the diameter of the suction line If there is a liguid flow from an open pipe into the sump the flow should be kept away from the suction inlet because the inflow will carry air down into the sump and air entering the suction line will reduce pump efficiency If it is necessary to position inflow close to the suction inlet install a baffle between the inflow and the in suction lines it must be the rigid wall reinforced type to prevent collapse under suction Using piping couplings in suction lines is
51. vers gauges or fittings from an overheated pump Liguid within the pump can reach boiling temperatures and vapour pressure within the pump can cause parts being disengaged to be ejected with great force After the pump cools drain the liquid from the pump by removing the casing drain plug Use caution when removing the plug to preventinjury to personnel from hotliguid As safeguard against rupture or explosion due to heat this pump is eguipped with a pressure relief valve which will open if vapour pressure within the pump casing reaches a critical point If overheating does occur stop the pump immediately and allow it to cool before servicing it Approach any overheated pump cautiously It is recommended that the pressure relief valve assembly be replaced at each overhaul or any time the pump casing overheats and activates the valve Never replace this valve with a substitute which has not been specified or provided by Remko Strainer Check If a suction strainer has been shipped with the pump or installed by the user check the strainer regularly and clean it as necessary The strainer should also be checked if pump flow rate begins to drop If a vacuum suction gauge has been installed monitor and record the readings regularly to detect strainer blockage Never introduce air or steam pressure into the pump casing or piping to remove a blockage This could result in personal injury or damage to the equipment If back flushing is
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