TECHNICAL SERVICE MANUAL
Contents
1. Place flat washers and lock washers on the studs then thread on the retaining nuts Tighten the nuts evenly to secure the mechanical seal to the stuffing box face Make sure the seal setting clips are in place and tighten the drive setscrews to the shaft Leave the setting clips in place until after the pump is installed on the drive unit Be sure and remove the clips before start up PSII SEAL 6 Make sure the shaft is clean and free of any nicks or burrs Lubricate the shaft with lube oil and slide the mechanical seal in place Rotate the seal installation tabs 90 degrees so they point towards the seal sleeve Adjust the position of the seal so the sleeve is evenly spaced between the tabs Place flat washers and lock washers on the studs then thread on the retaining nuts Tighten the nuts evenly to secure the seal to the stuffing box face Tighten the drive setscrews to the shaft Using a feeler gage make sure there is still an equal space between the sleeve and the retaining tabs Readjust if necessary Leave the seal installation tabs in position until the pump is installed on the drive unit and properly aligned Rotate the tabs 90 degrees before pump start up MECHANICAL SEAL NOTES 1 Vent air from stuffing box before start up The seal may fail prematurely if this is not done Preheat seal prior to introducing hot product Use of low pressure 2 4 psi continuous flow steam quench on the atmospheric side is r2. V belt That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on pump That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood FIGURE 1 Failure to follow above listed ILLUSTRATION OF SERIES 34 precautionary measures may result in JACKETED PUMP serious injury or death IDEX CORPORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA SAFETY INFORMATION AND INSTRUCTIONS IMPROPER INSTALLATION OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY OR DEATH AND OR RESULT IN DAMAGE TO PUMP AND OR OTHER EQUIPMENT VIKING S WARRANTY DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION OPERATION OR MAINTENANCE THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION OPERATION OR MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP PUMP MUST BE INSTALLED OPERATED AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES Symbol Legend SECTION TSM 430 AN or death BEFORE opening any liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc be sure that e Any pressure in the chamber has been completely
3. INSTRUCTIONS Series 34 and 434 jacketed pumps may be furnished with a relief valve head and a plain or jacketed relief valve as illustrated in Figures 10 and 11 EET ee et ou eier D dm il OU O RER Ing i Un SL PR S S OU OO LNT Ks mL FIGURE 11 PLAIN VALVE FIGURE 11 JACKETED VALVE Valve Cap Valve Body Adjusting Screw Lock Nut Valve Spring Poppet Cap Gasket Bonnet Gasket Spring Guide Bonnet SECTION TSM 430 ISSUE d PAGE 8 OF 9 DISASSEMBLY DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on pump That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precautionary measures may result in serious injury or death ASSEMBLY Follow the procedure outlined under Disassembly in reverse order If valve is removed for repairs be sure to replace in same position
4. Tilt the top of the head away from the pump slightly until the crescent enters the inside diameter of the rotor and rotate the idler until its teeth mesh with the rotor teeth Do not damage the head gaskets Tighten the head capscrews or nuts and then check the end clearance If the pump shaft cannot be rotated more gaskets must be added If however the pump has any noticeable end play remove enough gaskets so the pump has no appreciable end play but still turns freely PSII is a registered trademark of FlowServ PACKED PUMPS 6 Pack the pump It is good practice to install a set of new packing The pump should be packed with packing suitable for the liquid being pumped Cut the packing into individual rings that wrap exactly around the shaft Install and seat each ring one at a time staggering the ring joints from one side of the shaft to the other Lubricate the packing rings with oil grease or graphite to aid in assembly A length of pipe or tubing will help in seating the packing rings Install the packing gland and nuts The gland must enter the stuffing box at least one eighth of an inch after tightening the packing gland nuts Be sure the packing does not wedge between the stuffing box and the gland as this may split the stuffing box MECHANICAL SEAL PUMPS X 100 amp X 200 6 Make sure the shaft is clean and free of any nicks or burrs Lubricate the shaft with lube oil and slide the mechanical seal in place
5. adjusting screw caps must always point towards suction side of the pump If pump rotation is reversed position of the relief valve must be changed Pressure relief valves cannot be used to control pump flow or regulate discharge pressure For additional information refer to Viking Pump s Technical Service Manual TSM 000 and Engineering Service Bulletin ESB 31 THE PUMP must be installed in a matter that allows safe access for routine maintenance and for inspection during operation to check for leakage and monitor pump operation ROTATION Viking pumps operate equally well in a clockwise or counter clockwise rotation Shaft rotation determines which port is suction and which is discharge Port in area where pumping elements gear teeth come out of mesh is suction port PRESSURE RELIEF VALVES 1 Viking pumps are positive placement pumps and must be provided with some sort of pressure protection This may be a relief valve mounted directly on the pump an in line pressure relief valve a torque limiting device or a rupture disk 2 There are relief valve options available on these pumps Options may include a plain or a jacketed relief valve depending on the pump size Pumps equipped with a jacketed head plate are generally not available with a relief valve 3 f pump rotation is to be reversed during operation pressure protection must be provided on both sides of pump 4 Relief valve adjusting screw cap must always point
6. towards suction side of pump If pump rotation is reversed remove pressure relief valve and turn end for end 5 Pressure relief valves cannot be used to control pump flow or regulate discharge pressure For additional information on pressure relief valves Refer to Technical Service Manual TSMO000 and Engineering Service Bulletin ESB 31 MAINTENANCE Series 34 and 434 jacketed pumps are designed for long trouble free service life under a wide variety of application conditions with a minimum of maintenance however the following should be considered 1 LUBRICATION External lubrication must be applied slowly with a handgun to all lubrication fittings every 500 hours of operation with multi purpose grease NLGI 2 Do not over grease Applications involving very high or ITEM NAME OF PART ITEM SS Mechanical Seal 8 Packing Retainer Washer s Lockwasher 3e Casing Gcr 4 Farwen Pipe Pig e Pacing Gand fna llerana Busting sembly Not mus RetervameGasret Fr Packing ln weene Date Rit Vawe Capers NAME OF PART low temperatures will require other types of lubrication Refer to Engineering Service Bulletin ESB 515 Consult factory with specific lubrication questions 2 PACKING ADJUSTMENT New packed pumps generally require some initial packing adjustment to control leakage as packing runs in Make initial packing adjustments carefully and do not over tighten the packing glan
7. Head Jacked and ler Pin Assembly s Packing Pere ome Reeve O s Packing RetanerWasher 48 Casing Waited Netus Reiervave Gesiet s Rotor Bearing Steve Busting 19 Pipe Pug Netus Reiervave Capscrews aw RotorBearngSieeve ofe SSC SSCP CS FIGURE 7 EXPLODED VIEW SERIES 34 amp 434 PUMPS M SIZE Pw L ese 22 Rotorand Shan asserby a Fiat washer ia Thrust nasher Rotor Ca erana Bushing Asserby Ca Hea Gasketset o i Ca wer i ESCH e Pacine Gans 5 ss s Packing Retaner Washer 48 Casing veee D s Reeve s Rotor Bearing Sleeve Bushing 9 PipePug Netus Reletvawe Gasket 10 Ror Bearing Seve o Gee Not lus Relet vate Cansorene SECTION TSM 430 ISSUE d PAGE 5 OF 9 FIGURE 8 EXPLODED VIEW SERIES 34 amp 434 PUMPS N SIZE zm Rolorand Shantassemby Ca ler and Bushing Assembly 25 wen o Ca Head GasketSe i CS NAME OF PART p t WMechanicalseat d C as 2 Nt Im Thrust Washer Rotor Bearing Sleeve Ps sue E 7 mm 5 cesis acies Cham Reevaw s Packing Retainer Washer 19 PinePug Netus Reievawe Gast s Rotor Bearing Sleeve Busting 20 Gase norimus Reie
8. TECHNICAL SERVICE MANUAL cu tsm430 JACKETED ASPHALT PUMPS pace 4oro SERIES 34 AND 434 SIZES HL KK LQ Q M N CONTENTS Introduction uoo kx orum el mok Oe Re e o 1 Special Information lcs 1 Safety Information 2 Maintenance ln 3 Disassembly 20000008 6 Assembly 2a eee s Pa ee Sb RORCR E CE e eR 7 Valve Instructions 00 8 INTRODUCTION The illustrations used in this manual are for identification purposes only and should not be used for ordering parts Secure a parts list from the factory or a Viking representative Always give complete name of part part number and material with the model and serial number of the pump when ordering repair parts FIGURE 2 CUTAWAY VIEW OF SERIES 434 UNMOUNTED PUMP UNITS JACKETED PUMP PACKED MECH SEAL Units are designated by the SPECIAL INFORMATION unmounted pump model numbers followed by a letter indicating drive style DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc This manual deals exclusively with series 34 and 434 Be sure Jacketed General Purpose Pumps Refer to Figures 1 1 That in th h ber h through 11 for general configuration and nomenclature used S at any pressure in the chamber has in this manual been completely vented through the suction or discharge lines or other appropriate openings or connections V
9. The valve cap should point towards the suction port CAUTION Before starting the pump be sure all drive equipment guards are in place Failure to properly mount guards may result in serious injury or death IMPORTANT In ordering parts for relief valve on head always be sure to give Model and Serial Number of pump as it appears on nameplate and the name of the part wanted When ordering springs be sure to give the pressure setting desired TECHNICAL SERVICE MANUAL JACKETED ASPHALT PUMPS SERIES 34 AND 434 SIZES HL KK LQ Q M N SECTION TSM 430 PAGE 9 OF 9 ISSUE D VIKING IEEE PUMP WARRANTY Viking warrants all products manufactured by it to be free from defects in workmanship or material for a period of one 1 year from date of startup provided that in no event shall this warranty extend more than eighteen 18 months from the date of shipment from Viking If during said warranty period any products sold by Viking prove to be defective in workmanship or material under normal use and service and if such products are returned to Viking s factory at Cedar Falls lowa transportation charges prepaid and ifthe products are found by Viking to be defective in workmanship or material they will be replaced or repaired free of charge FOB Cedar Falls lowa Viking assumes no liability for consequential damages of any kind and the purchaser by acceptance of delivery assumes all liability for the conseque
10. d After initial adjustment occasional inspection will reveal the need for packing gland adjustment and or replacement of the packing See instructions in disassembly and reassembly regarding re packing the pump 3 END CLEARANCE ADJUSTMENT After long term operation it is sometimes possible to improve the performance of the pump without major repair through adjustment of end clearance of the pump Refer to instructions under Step 3 of Assembly page 7 4 CLEANING PUMP It is good practice to keep the pump as clean as possible This will facilitate inspection adjustment and repair work and help prevent omission of lubrication to fittings covered or hidden with dirt 5 STORAGE If pump is to be stored or not used for any appreciable length of time it should be drained and a light coat of lubricating and preservative oil should be applied to the internal parts Lubricate all fittings Be sure to drain all steam jacket chambers to prevent freezing during cold weather Tighten all assembly bolts before the pump is put into service after being stored SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 34 and 434 pumps These tools are in addition to standard mechanics tools such as open end wrenches pliers screwdrivers etc Most of the items can be obtained from an industrial supply house 1 Soft Headed Hammer 2 Packing hooks flexible packed pumps Large for 0 375 inch and up cross section pac
11. ecommended Failure to use a steam quench could result in premature seal failure For double seals pressurize seal chamber before startup Do not start pump until it is fully heated Mechanical seal will fail almost instantly if hard product is in the seal chamber Do not use the PSII cartridge lip seal for filled asphalt or any product containing abrasives SECTION TSM 430 ISSUE d PAGE 7 OF 9 7 When converting an existing installation to a mechanical seal special attention must be placed on the condition of the pump All pumps should be inspected to make sure the rotor shaft is in good condition Any shaft wear due to packing will result in mechanical seal leakage In general the rotor and shaft assembly should be replaced N size pumps can use the same rotor bearing sleeve assembly without modification Outboard face of this assembly will need to be cleaned to make sure there is a good surface for the mechanical seal to seal against 8 Most asphalt pumps are V Belt driven Packing is quite tolerant of any misalignment but mechanical seals are not Make sure sheaves are aligned properly see TSM 000 and that the rotor shaft is properly supported with a pillow block bearing Itis also important to make sure the mechanical seal is properly aligned with the rotor shaft This is done at the time of seal installation Be sure to recheck alignment when the rotor shaft is inserted in the pillow block bearing PRESSURE RELIEF VALVE
12. king Arbor Press Allen wrenches for mechanical seals 5 Feeler gage set for mechanical seals FIGURE 3 EXPLODED VIEW SERIES 34 amp 434 PUMPS HL SIZE NAME OF PART Head Gasket Set 146 Idler Pin Head Jacketed and Idler Pin Assembly a Capscrew Not Illus Relief Valve SECTION TSM 430 ISSUE d PAGE 3 OF 9 FIGURE 4 EXPLODED VIEW SERIES 34 amp 434 PUMPS KK SIZE Ds a o9 eem Ca Fiatwasher EE 20 vesc acketed and Wer Pis Assembly sfs Ls ense Ca emm Le Packing Gand 44 Casing taces Dem Reiervae PITT e bm MENT BIED IR w St X ed 16 amp T FIGURE 5 O EXPLODED VIEW SERIES 34 amp 434 PUMPS LQ SIZE p wemanasen n Pe Pg Ca lerand Bushing Assembiy ee 9 eet x Wems oo Ls ease 5 we x Head GasketSet 4 Fawn faf m foem SSS Ps sus i ss Pine Pg 25 Head Jacked and ler Pn Assembly re 16 Casing acres a carscrow ooo SES Packing Gland SECTION TSM 430 ISSUE d PAGE 4 OF 9 FIGURE 6 EXPLODED VIEW SERIES 34 amp 434 PUMPS Q SIZE 1 Wecharialsea Pipe Pg 21 Rotorand Sra assemby ee L ese CS er ana Bushing Assemby ca Fiat washer Dress Rotor RECH EC Ds Ls ww 3s foer Ls Packing Ging 5 ws 26
13. nces of the use or misuse of Viking products by the purchaser his employees or others Viking will assume no field expense for service or parts unless authorized by it in advance Equipment and accessories purchased by Viking from outside sources which are incorporated into any Viking product are warranted only to the extent of and by the original manufacturer s warranty or guarantee if any THIS IS VIKING S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED WHICH ARE HEREBY EXCLUDED INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE No officer or employee of IDEX Corporation or Viking Pump Inc is authorized to alter this warranty IREX DEXCOBFORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA 5 2007 Viking Pump Inc All rights reserved
14. pump can be assembled ASSEMBLY 1 Thrust washers used in Q M and N size pumps should be assembled on the rotor hub and rotor bearing sleeve Put the plain washer on the two locating pins on the rotor hub Put the grooved face washer on the pins on the rotor bearing sleeve with the grooved face toward the rotor Remove all burrs and rough surfaces from the rotor and shaft and assemble in the casing Lubricate the rotor shaft with lube oil and start the shaft through the rotor bearing sleeve or casing bushing Slowly turn the rotor and push it into the casing as far as it will go Place the head gaskets on the head The proper amount of gaskets should be used to provide the necessary end clearance within the pump so it turns freely with no appreciable endplay The Gasket Table below gives the normal amount of gaskets used on each pump NORMAL AMOUNT USED INCH ONE SET OF GASKETS CONSISTS OF THE FOLLOWING PUMP MODELS HL 34 amp 434 010 020 1 005 2 007 KK 34 amp 434 015 025 2 007 1 015 LQ 34 amp 434 025 035 1 015 2 006 Q M N 34 amp 434 020 035 2 015 1 006 FIGURE 9 GASKET TABLE Lubricate the idler pin with lube oil and place the idler and bushing assembly on the idler pin The head can now be assembled on the pump Make sure itis installed in the correct position See Disassembly Step 1 Note page 6
15. rvaweCapecews qw RotorBearingsteeve 2 Nt CCS RR CCS n meme zs A 1 DISASSEMBLY Idler Pin distance between the port connections to allow for proper flow of liquid through the pump 1 Allow pump to cool Remove the head from the pump DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on pump That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precautionary measures may result in serious injury or death If pump is furnished with a relief valve it need not be removed from head or disassembled at this point For mechanical seal pumps remove any flush lines going to the mechanical seal if this has not already been done CAUTION Do not allow the idler to fall from the idler pin Tilting the head up as it is removed will prevent this occurrence Avoid damaging the head gasket if po
16. ssible For pumps with X 100 or X 200 mechanical seals insert the setting clips back in place For pumps with PSII seals rotate the installation tabs 90 degrees so they contact the sleeve Loosen the set screws that secure the seal sleeve to the shaft Remove the nuts washers and lockwashers holding the mechanical seal and slide the seal assembly from the shaft Carefully remove rotor and shaft from the pump CAUTION Avoid damaging the rotor bearing sleeve bushing NOTE Mark the head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump head should be properly positioned toward and equal SECTION TSM 430 ISSUE d PAGE 6 OF 9 THRUST WASHERS Rotor thrust washer and rotor bearing sleeve thrust washer used in Q M and N size pumps should be removed examined for excessive wear and replaced if necessary These thrust washers are located on the hub of the rotor and the casing end of rotor bearing sleeve If the rotor bearing sleeve casing or idler bushing shows signs of wear it should be replaced All parts should be checked for wear before the pump is put together When making major repairs such as replacing a rotor and shaft it is usually considered advisable to also install a new head and idler When making minor repairs where only an idler bushing and idler pin are required other new parts are usually not necessary When all the necessary parts are available the
17. ury or death failure to follow the indicated instruction may cause damage to pump and or other equipment INSTALL pressure gauges sensors next to the pump suction and discharge connections to monitor pressures USE extreme caution when lifting the pump Suitable lifting devices should be used when appropriate Lifting eyes installed on the pump must be used only to lift the pump not the pump with drive and or base plate If the pump is mounted on a base plate the base plate must be used for all lifting purposes If slings are used for lifting they must be safely and securely attached For weight of the pump alone which does not include the drive and or base plate refer to the Viking Pump product catalog DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is mounted on a pump that is operating AVOID contact with hot areas of the pump and or drive Certain operating conditions temperature control devices jackets heat tracing etc improper installation improper operation and improper maintenance can all cause high temperatures on the pump and or drive THE PUMP must be provided with pressure protection This may be provided through a relief valve mounted directly on the pump an in line pressure relief valve a torque limiting device or a rupture disk If pump rotation may be reversed during operation pressure protection must be provided on both sides of pump Relief valve
18. vented through the suction or discharge lines or other appropriate openings or connections The pump drive system means motor turbine engine etc has been locked out or otherwise been made non operational so that it cannot be started while work is being done on the pump You know what material the pump has been handling have obtained a material safety data sheet MSDS for the material and understand and follow all precautions appropriate for the safe handling of the material BEFORE operating the pump be sure all drive guards are in place DO NOT operate pump if the suction or discharge piping is not connected DO NOT place fingers into the pumping chamber or its connection ports or into any part of the drive train if there is any possibility of the pump shafts being rotated DO NOT exceed the pumps rated pressure speed and temperature or change the system duty parameters from those the pump was originally supplied without confirming its suitability for the new service BEFORE operating the pump be sure that e Itis clean and free from debris e all valves in the suction and discharge pipelines are fully opened All piping connected to the pump is fully supported and correctly aligned with the pump Pump rotation is correct for the desired direction of flow ISSUE d PAGE 2 OF 9 Danger Failure to follow the indicated instruction may result in serious injury Warning In addition to possible serious inj
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