edition 27.04.07 - Toyo Pumps Europe
Contents
1. USER S MANUAL Toyo Heavy duty slurry pumps TOYO PUMPS EUROPE Edition 27 07 2007 SAFETY INSTRUCTIONS Edition 27 04 2007 TOYO PUMPS EUROPE User s manual for Toyo pumps type GR 2 3 10HP This user s manual will help you to maintain your Toyo pump in optimum working condition for a long time Please read carefully before using the pump and keep for future reference Take note of the serial number which you can find on the identification plate of your pump The manufacturer reserves the right to modify specifications and concept of these products without previous notice Edition 27 04 2007 TOYO PUMPS EUROPE Parc Industriel Sud Zone II Rue de l Industrie 41 Belgium Tel 32 67 64 55 37 Fax 32 67 64 55 31 E mail info toyopumpseurope com Web site www toyopumpseurope com TOYO PUMPS EUROPE Edition 27 04 2007 TOYO PUMPS EUROPE CONTENTS Introduction Precautions before operating Notes on driving Maintenance and troubleshooting Points to be attentive Troubleshooting list Disassembling procedures Assembling procedures Technical specifications Pump performance curve Dimensions Spare parts list Exploded view drawings a ROS Sc wee 15 18 Edition 27 04 2007 INTRODUCTION A wrong utilisation and an inadequate manipulation of the pump will cause unsatisfactory performances and early troubles So please read this instruction manual carefully before operat2. side d x Unscrew the stay bolts 47A and remove the suction cover 41 Remove the packing s 42 e Unscrew the impeller nut 40 and the impeller collar 39 Remove the impeller 37 the key 36 f Unscrew the set bolts 6A and remove the vortex casing 38 with the collar 44 g Remove the distance collar 43 TOYO PUMPS EUROPE 8 Edition 27 04 2007 b c d e f g a o c 3 Disassembling of the shaft sealed section Unscrew one of the oil inlet bolts 48A and its O ring 48B and collect the lubrication oil in a recipient Unscrew the set bolt 34A and remove the oil chamber cover 32 Remove the packing 33 Remove the shaft sleeve 30 from the shaft 17 Extract the moving part of the mechanical seal 27A from the shaft 17 Unscrew the set bolts 26A to extract the housing 28 and remove the packing 29 Extract the fixed parts of the mechanical seal from the housing 28 and the oil chamber cover 32 Remove the oil seal 31 from the oil chamber cover 32 Place the pump vertically upside down Unscrew the set bolts 34A from the under cover 35 to extract the roller bearing 23 shaft 17 rotor 15 and roller bearing 14 assembly Unscrew the set bolts 26A from the bearing cover 25 to extract under cover 35 Remove the packing 16 If it is necessary extract the roller bearings 14 23 4 Disassem
3. arity may not exceed 0 03 mm d Clean carefully the contact surfaces that are in contact with the packing of the mechanical seal e Apply oil on the floating seats of the mechanical seal Pay sufficient attention to handle the mechanical seal Its hard and brittle f When the assembling is completed check the assembly by turning the shaft by hand Make a leakage check Put the under cover under pressure of 3 kg cm through the lubricating hole of the pump Verify with a pressure gauge that this pressure maintains for at least 3 minutes g h x Fill up the under cover with oil Type and oil quantity is mentioned in the technical specification sheet of the pump TOYO PUMPS EUROPE 10 Edition 27 04 2007 3 Other seals Renew all seals after disassembling 4 Electric connection Connect the pump as shown on the drawing here below Alimentation 3 x 400 V Thermal Terminal board protection Not forget to remake the full one with the oil bath by the opening envisaged for this purpose Type and quantity of oil are specified in the technical features of the pump TOYO PUMPS EUROPE 11 Edition 27 04 2007
4. bling of the motor section Return the pump and disconnect the six electric wires coming out of the motor from the terminal board 52A and from the thermal protection 13A Unscrew the set bolts 6A and remove the upper cover 12 from the motor case 20 Remove the packing 15 Make sure not to hurt the electric wires coming out of the stator and the winding The disassembling of the pump is now finished Take care to clean all parts before reassembling them TOYO PUMPS EUROPE 9 Edition 27 04 2007 ASSEMBLING PROCEDURES To reassemble the pump it is sufficient to follow the disassembling procedures in opposite direction Please find here below the specific assembling instructions 1 Bearings a The bearings may be mounted by pression exerted on the internal ring of the bearing by the instrumentality of a jig Do not forget to grease the shaft and the internal ring of the bearing before mounting b Nevertheless it is recommended to heat the bearings before mounting In this case heat up the bearings by induction or in oil at maximum 120 C and slide them on the shaft Afterwards let the bearings cool down by air O Use only grease for bearing lubrication or lithium grease 2 Mechanical seal a This job should be done with care and in clean circumstances b x Do not open the package of the mechanical seal before starting the assembling O The eccentricity and the perpendicul
5. ion PRECAUTIONS BEFORE OPERATING 1 Power supply Check the power supply voltage and frequency by referring to the identification plate on the pump Operation of the pump on a different power voltage from the specified voltage will cause impossibility of pumping up and motor burning 2 Grounding Make sure to connect the pump correctly to the earth The earth cable is the green and yellow coloured one 3 Rotation direction As to the rotating direction counterclockwise rotation viewing from the suction intake side lower side of the pump is the correct way of rotating The rotation direction is mentioned on the identification plate of the pump After connecting the pump let it turn a short instant out of the liquid to be pumped in order to check the motor direction by observing the agitator Attention the agitator can detach itself when turning in opposite direction Should the electric motor turn in the wrong direction you only need to invert two alimentation wires Rotation in the air for a longer period of time causes damages to the seals The rotating direction of the agitator can be verified instantaneously Never drive the pump in opposite direction as it will cause early damages to the pump 4 Protection of electric motor It is in any case necessary to protect the pump with a correctly calibrated thermal protection to avoid any overload and to install a start stop switch The supplier of the pump can advise you
6. m e When the level of the pumped liquid is insufficient it will cause noisy functioning and generate an abnormal wear In this case add liquid or stop the pump and wait for the liquid to rise f Oversized materials such as pieces of wood etc have nevertheless the effect of the agitator propensity to present themselves at the entrance of the pump which has to be equipped with iron bars with holes of the same dimension as the holes of the strainer Consult your supplier The density of the pumped liquid can be verified by raising or descending the pump A to heavy density can provoke the blockage of the discharge hose and of the pump and make pumping impossible Heavy densities have to be avoided g TOYO PUMPS EUROPE 2 Edition 27 04 2007 h oO c d x 2 Use a sufficient resistant chain which will be attached to the lifting handle provided on the pump for transporting or handling the pump The angle between the two parts of the chain may not overshoot 60 degrees Never suspend the pump by its alimentation cable When the pump is in duty it has to be immersed until the level indicated on the schema representing the dimensions of the pump Rinse the pump and the discharge hose with clean water before turning it off MAINTENANCE AND TROUBLESHOOTING Measure periodically the voltage of the alimentation current to verify that the pump works at the correct voltage The electric resistance of the mo
7. ow of the pump is to weak The pump turns in the opposite direction _ Inverse two of the three alimentation phases The level of the pumped liquid is insufficient Add to the level Obstruction at the entrance of the pump or at the discharge hose Verify and clean up Air in the discharge hose Place the hose as horizontal as possible Wear of the impeller and the impeller disc Adjust the space between the two parts as indicated in the technical characteristics The pump provided to work in 60 Hz is furnished in 50 Hz Consult your supplier Insufficient discharge pressure Consult your supplier TOYO PUMPS EUROPE 6 Edition 27 04 2007 e The thermal protection disconnects The density of the pumped liquid is to important Lower the density by lifting the pump and or by diluing the pumped materials Important voltage drop Replace the alimentation cable by a cable with correct section and length as indicated in the technical specification of the pump The impeller disc is in contact with the impeller Adjust the space between the two parts as indicated in the technical characteristics One of the phases is missing Complete inspection out of the liquid of the electric circuit going from the source untill the electric motor The pump provided to work in 50 Hz is furnished in 60 Hz Consult your supplier The electric motor is burned Consul
8. space between the floaters TOYO PUMPS EUROPE 4 Edition 27 04 2007 TROUBLESHOOTING LIST The pump is in duty but doesn t turn even as the switch is in ON position The pump emits no sound Electric alimentation problem Verify if the network is under tension and or the generator works properly Defective connection or breakdown of one of the alimentation wires Verify all connections and check the state of the wires Alimentation throw one single phase Verify the connections and fuses The pump emits a sound A foreign body blocs the agitator or is jammed between impeller and impeller disc Remove the foreign body The impeller disc is blocked against the impeller Adjust the space between the two parts as indicated in the technical characteristics A bearing is broken Replace the bearing Wire breakdown in one of the wires inside the winding of the stator Consult your supplier The stator is burned Consult your supplier TOYO PUMPS EUROPE 5 Edition 27 04 2007 The pump turns when the switch is in ON position but e The pump emits an abnormal sound A foreign body blocs the agitator or is jammed between impeller and impeller disc Remove the foreign body The impeller disc is in contact with the impeller Adjust the space between the two parts as indicated in the technical characteristics Defective bearing Replace the bearing e The fl
9. t your supplier TOYO PUMPS EUROPE 7 Edition 27 04 2007 DISASSEMBLING PROCEDURES Choose a dry and clean place to dismantle and reassemble your pump and install a base on which you can put the pump It is also wise to prepare a few small boxes in which you can put the small parts dismantled from the pump Prepare also some rags oil and tools The numbers mentioned between parenthesises in the description correspond to the parts numbers in the spare parts list 1 Disassembling of the electric cable a x Unscrew the set bolts 34A and remove the lead cover 7 b Dismantle the electric cable 1A of the terminal board 52A Remove the packing 8 c In case you want to replace the electric cable unscrew the set bolts 34A and remove the packing gland 3 Extract the cable from the lead cover 7 and detach the cable protection tube A 2 the set ring 4 and the cable protection tube B 5 2 Disassembling of the pump section a x Place the pump horizontally and fix it in such way that it can not move during the disassembling procedure b x Unscrew the cap nuts 47D and remove the strainer 46 O The cutter fan 45 is screwed normal right thread on the shaft 17 To dismantle the cutter fan hit it with a mallet or hammer by interposing a bronze or aluminium jig on one of the corners of the cutter fan Unscrew it in counterclockwise direction the pump seen from beneath aspiration
10. the adequate material TOYO PUMPS EUROPE 1 Edition 27 04 2007 5 Cabtyre cable a The use of a cabtyre cable which has an inferior section or a superior length then recommended can make the starting up of the pump impossible and provoke damages to the motor Concerning the characteristics of the cable to use please refer to the technical characteristics of the pump Verify that the length of the alimentation cable corresponds to the depth at which the pump has to work and this to avoid tearing out the cable c In case of lengthening the cable fixed to the pump with a second cable make sure not to submerge the connection between the two cables b 6 Discharge hose The diameter of the discharge hose fixed to the pump has to be adapted to the diameter of the hose nipple of the pump The discharge hose will at preference be fixed with half circular collars NOTES ON DRIVING a For your safety never touch the agitator when the pump is connected and never pass underneath the pump while it is suspended oO If possible avoid using the pump in conditions that provoke an overload See in particular to immerse the pump progressively until the material to pump is reached c Inspect the good working condition of the pump by verifying that the intensity of the current does not pass the value indicated on the identification plate of the pump d Avoid suspending the pump in such way that it gets buried at the botto
11. tor has to be verified at least once a month If the resistance of the motor is inferior to 100M Ohm the winding of the electric motor has to be dried and the tightness of the cables checked etc The oil capacity in the under cover has to be verified every 500 hours Therefore place the pump horizontally If needed add oil as specified in the table of technical characteristics of the pump normal or biodegrading through the opening provided to this end If the presence of water in the oil is established whitish emulsion or if the oil contains solid particles mud etc it means that the seals are defective Their replacement is then required The quantity of oil in the under cover of the pump is specified in the technical specifications of the pump If the flow of the pump is diminishing the space between the impeller disc and the impeller has to be checked The recommended space is indicated in the technical specifications of the pump TOYO PUMPS EUROPE 3 Edition 27 04 2007 POINTS TO BE ATTENTIVE a The maximum liquid temperature for the standard versions is 60 C b Avoid that pumped materials ex mud are sticked on the motor part of the pump This can provoke an abnormal heating of the motor Clean the pump if this occurs c If air occurs in the discharge hose it happens that the liquid can not be pumped any more In that case verify if the discharge hose is placed as horizontal as possible ex avoid to large
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