Viking Pump with Motor and Gear Reduction Drive
Contents
1.2. CONNECTIONS 2 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 3 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 1 Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump head must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Remove head from pump Do not allow idler to fall from idler pin Tilt top of head back when removing to prevent this Avoid damaging head gasket If pump is furnished with pressure relief valve it need not be removed from head or disassembled at this point Refer to Pressure Relief Valve Instructions page 14 If pump has jacketed head plate it will separate from head when it is removed The gasket between head and jacket head plate must be totally removed Use new gasket when assembling pump 2 Remove idler and bushing assembly 3 Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Bend up tang of lockwasher and with a spanner wrench remove loc
3. following instructions must be carefully followed 1 Carefully remove valve cap which covers adjusting screw Loosen locknut which locks adjusting screw so pressure setting will not change during operation of pump 2 Install a pressure gauge in discharge line for actual adjustment operation 3 Turn adjusting screw in to increase pressure and out to decrease pressure 4 With discharge line closed at a point beyond pressure gauge gauge will show maximum pressure valve will allow while pump is in operation IMPORTANT In ordering parts for pressure relief valve always give model number and serial number of pump as it appears on nameplate and name of part wanted When ordering springs be sure to give pressure setting desired IREX VIKING PUMP INC PER EERE A Unit of IDEX Corporation SECTION TSM141 1 ISSUE C VIKING PUMP 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 manufacturers 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 i ey Te VIKING PUMP INC Copyright 2000
4. Bonnet 10 Bonnet DISASSEMBLY 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 Mark valve and head before disassembly to insure proper reassembly 1 Remove valve cap 2 Measure and record length of extension of adjusting screw Refer to A on Figures 17 18 and 19 3 Loosen locknut and back out adjusting screw until spring pressure is released 4 Remove bonnet spring guide spring and poppet from valve body Clean and inspect all parts for wear or damage and replace as necessary ASSEMBLY Reverse procedures outlined under Disassembly If valve is removed for repairs be sure to replace in same position Relief valve adjusting screw cap must always point towards suction side of pump If pump rotation is reversed remove relief valve and turn end for end Refer to Figures 1 2 3 and 4 page 1 FAILURE TO PROPERLY MOUNT GUARDS MAY RESULT IN SERIOUS INJURY OR DEATH TECHNICAL SERVICE MANUAL VI KING HEAVY DUTY BRACKET MOUNTED PUMPS NEE Ae SERIES 125 and 4125 PUMP SIZES G LL PRESSURE ADJUSTMENT If a new spring is installed or if pressure setting of pressure relief valve is to be changed from that which the factory has set the
5. E Mfg Viking Modes Stock No SPGP003 2 SerialNo Viking Pump with motor and gear reduction drive Motor Ajax Electric Motors Type DFT100L4 23 450 volt 60 Hz 13 6 6 8 amps 5 hp 3 phase Pump runs 150 gpm 520 rpm Works best pumping lubricating fluids not water as the rotary gears are cast iron Cost new 2 100 TECHNICAL SERVICE MANUAL VIKING HEAVY DUTY BRACKET MOUNTED PUMPS oa ae 141 1 SERIES 125 and 4125 PUMP SIZES G LL ISSUE C CONTENTS Special Information 2 Maintenance 2 Packed Pumps 3 Mechanical Seal Pumps Standard Rubber Bellows Type Sizes G H HL K KK L LQ amp LL 6 Optional Teflon Seal 9 Standard Rubber Bellows Type Sizes AK amp AL 11 FIGURE 1 Thrust Bearing Adjustment 13 Sizes G H and HL Installation of Carbon Graphite Bushings 13 Pressure Relief Valve Instructions 14 INTRODUCTION The illustrations used in this manual are for identification purposes only and cannot be sed for ordering parts Obtain a parts list from the factory or a Viking representative Always give complete name of part part number and material with model number and serial number of pump when ordering repair parts The unmounted pump or pump unit model number and serial number are on the nameplate FIGURE 2 In the Viking model number system basic size letters are Sizes AK and AL combined with series number 125 and 4125 indicating both unmounted or mounted pump unit UNMOUNTED PUMP PACKED M
6. ECH SEAL G125 G4125 Units ah designed by fi be ee unmounte pump mode numbers followed by a letter HL125 HL4125 indicating drive style AK125 AK4125 AL125 AL4125 K125 K4125 V Vbelt KK125 KK4125 Di FIGURE 3 D Direct Connected Sizes K KK and LL L125 L4125 R Viking Speed Reducer LQ125 LQ4125 P Commercial Speed Reducer LL125 LL4125 This manual deals only with Series 125 and 4125 Heavy Duty Bracket Mounted Pumps Refer to Figures 1 thru 19 for general configuration and nomenclature used in this manual Pump specifications and recommendations are listed in Catalog Section 141 Seres 125 and 4125 Heavy Duty Bracket Mounted Pumps ai FIGURE 4 IREX VIKING PUMP INC Sizes LQ and LL DEY CORPORATION A Unit of IDEX Corporation SPECIAL INFORMATION DANGER BEFORE OPENING ANY VIKING PUMP LIQUID CHAMBER PUMPING CHAMBER RESERVOIR RELIEF VALVE ADJUSTING CAP FITTING ETC BE SURE 1 THAT ANY PRESSURE IN CHAMBER HAS BEEN COMPLETELY VENTED THROUGH SUCTION OR DISCHARGE LINES OR OTHER APPROPRIATE OPENINGS OR CONNECTIONS 2 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 3 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 FOL
7. ER RESERVOIR RELIEF VALVE ADJUSTING CAP FITTING ETC BE SURE 1 THAT ANY PRESSURE IN CHAMBER HAS BEEN COMPLETELY VENTED THROUGH SUCTION OR DISCHARGE LINES OR OTHER APPROPRIATE OPENINGS OR CONNECTIONS 2 THAT THE DRIVING MEANS MOTOR TURBINE ENGINE ETC HAS BEEN LOC KED OUT OR MADE NON OPERATIONAL SO THAT IT CANNOT BE STARTED WHILE WORK IS BEING DONE ON PUMP 3 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 11 Idler and Bushing Idler Bushing 7 Bearing Spacer Collar Inner 16 Pipe Plug 8 Ring Half Round 17 Grease Fitting o End Cap Inner DISASSEMBLY DANGER Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump head must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Remove head from pump Do not allow idler to fall from idler pin Tilt top of head back when removing to prevent this Avoid damaging head gasket If pump is furnished w ith pressure relief valve it need not be removed from head or disassembled at this point Refer to Pressure Relief Valve Instructions page 14 If pump has jacketed head plate it will separ
8. LOW ABOVE LISTED PRECAUTIONARY MEASURES MAY RESULT IN SERIOUS INJURY OR DEATH ROTATION Viking pumps operate equally well in a clockwise or counterclockwise rotation Shaft rotation determines which port is suction and which is discharge Port in area where pumping elements gear teeth come out of meshis suction port PRESSURE RELIEF VALVES 1 Viking pumps are positive displacement pumps and must be provided with some sort of pressure protection This may be a relief valve mounted directly on the pump an inline pressure relief valve a torque limiting device or a rupture disk 2 There are relief valve options available on those pump models designed to accept a relief valve Options may include a return to tank relief valve and a jacketed relief valve Pumps equipped with a jacketed head plate are generally not available with a relief valve 3 If pump rotation is reversed during operation pressure protection must be provided on both sides of pump 4 Relief valve adjusting screw cap must always point towards suction side of pump If pump rotation is reversed remove pressure relief valve and turn end for end Refer to Figures 1 2 3 and 4 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 TSMO0O and Engineering Service Bulletin ESB 31 SPECIAL INFORMATION SPECIAL MECHANICAL SEALS can be in
9. NET OUTER END CAP LOCKNUT INNER END CAP POSNE LIP SEAL INNER END CAP SCREW BRACKET VALVE CAP PACKING RETAINING WASHER BRACKET GASKET VALVE GASKET FIGURE 5 Cutaway View of G 125 with Callouts Exploded View of Models G125 H125 HL125 AK125 AI 125 K125 KK125 L125 LQ125 and LL125 Model KK125 shown 7 7 4 amp a 40 a amp eee amp ee a fa T r ie r il T TA T l 1 T T T Eg T T T S 32 EF ER cry 4 ry 3 ra l j j I j j i i i i i E j i i 4 I j f i i aa amet i l i r ah ae i i ar va n _ I Col D did 4 A i b w CEDG vat a 1 E H ja m rE l mi ias i i V e e a a a RT rioa o Packing en Packing Gland Nu 20 Casing 29 Jacketed Head Paie Packing Gland Capscrew 4 Lip Seal for End Cap 13 Packing Bearing Spacer Oollar Outer Packing Retaining Washer Idler and Bushing 6 Bal Bearing 45 Bracket Bushing Grease Fitting 25 Head Gasket 8 Png Ha Round Not GHAD 17 Bracket and Bushing 26 fern J SSS o End Cap nner apsorew for Bracket 27 Head andiderPin SSS 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 CHAMBER HAS BEEN COMPLETELY VENTED THROUGH SUCTION OR DISCHARGE LINES OR OTHER APPROPRIATE OPENINGS OR
10. and inner diameter of seal housing bore with non detergent SAE 30 weight oil 5 Start seal seat in seal housing bore refer to Figure 9 If force is necessary protect seal face with a clean cardboard disc and gently tap it in place with a piece of w ood COAT SEAL SEAT AND SEAL HOUSING BORE WITH NON DETERGENT SAE 30 WEIGHT OIL BEFORE ASSEMBLY BRACKET SEAL HOUSING BRACKET BORE SEAL SEAT BRACKET BUSHING LUBRICATION GROOVE IN 6 00 O CLOCK POSITION FIGURE 9 6 Place tapered installation sleeve on shaft refer to Figure 10 Sleeve is furnished with H HL K KK L LO and LL size replacement mechanical seals Coat rotor shaft tapered installation sleeve and inner diameter of mechanical seal rotary member with a generous amount of non detergent SAE 30 weight oil Petrolatum may ke used but grease is not recommended LIP SEAL FOR SEAL CHAMBER SPRING MECHANICAL SEAL ROTARY MEMBER TAPERED INSTALLATION SLEEVE COAT ROTOR SHAFT TAPERED INSTALLATION SLEEVE AND INNER DIAMETER OF MECHANICAL SEAL WITH NON DETERGENT SAE 30 WEIGHT OIL BEFO RE ASSEMBLY FIGURE 10 ROTOR HUB SPRING MECHANICAL SEAL ROTARY MEMBER FIGURE 11 7 Place seal spring on shaft against rotor hub Refer to Figure 11 8 Slide rotary member lapped contact surface facing away from spring over installation sleeve on shaft until it is against spring Do not compress spring 9 Coat rotor shaft with non detergent SAE 30
11. ate from head when it is removed The gasket between head and jacket head plate must be totally removed Use new gasket when assembling pump Remove idler and bushing assembly Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Bend up tang of lockwasher and with a spanner wrench remove locknut and lockwasher from shaft Rotate shaft so that the two setscrews for set collar can be seen through the seal access hole on left side of pump viewed from shaft end These two setscrews must be loosened before shaft can be removed from pump Refer to Figure 15 Remove seal holder nuts seal holder plate and capscrews Seal holder cannot be removed until shaft is removed Tap shaft forward approximately 0 5 inch and remove pair of half round rings under inner spacer collar Carefully remove rotor and shaft to avoid damaging bracket bushing Remove seal holder seal seat and rotary member of seal from side opening in bracket 10 11 12 Loosen the four setscrews over outer and inner end caps With spanner wrench remove both end caps and lip seals Remove ball bearing and spacer collars Refer to Figure 6 page 4 Clean all parts thoroughly and examine for wear or damage Check lip seals ball bearing bushings and idler pin and replace if necessary Check all other parts for nicks burrs excessive wear and replace if necessary Wash bearings in clean solvent Blow out b
12. ead must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Remove head from pump Do not allow idler to fall from idler pin Tilt top of head back when removing to prevent this Avoid damaging head gasket If pump is furnished with pressure relief valve it need not be removed from head or disassembled at this point Refer to Pressure Relief Valve Instructions page If pump has jacketed head plate it will separate from head when it is removed The gasket between head and jacket head plate must be totally removed Use new gasket when assembling pump 2 Remove idler and bushing assembly 3 Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Bend up tang of lockwasher and with a spanner wrench remove locknut and lockwasher from shaft There is no lockwasher on G size pump 4 Tap shaft forward approximately 0 5 inch and remove pair of half round rings under inner spacer collar There is no pair of half round rings on G H and HL size pumps 5 Carefully remove rotor and shaft to avoid damaging bracket bushing 6 Remove rotary member of seal from shaft and stationary seal seat from bracket 7 Loosen setscrews Two for G H and HL size pumps four for all other sizes With spanner wrench remove both end caps and lip seals Remove ball bearing and spacer collars Refer to Figure 6 page 4 8 Examine seal chamber l
13. ean then lubricate with non detergent SAE 30 weight oil and check for roughness Roughness can be determined by turning outer race by hand 11 Casing can be checked for wear or damage while mounted on bracket ASSEMBLY 1 Install bracket bushing If bracket bushing has a lubrication groove install bushing with groove at 6 00 o clock position in bracket If carbon graphite refer to Installation of Carbon Graphite Bushings page 13 2 Coat shaft of rotor shaft assembly with non detergent SAE 30 weight oil Start end of shaft in bracket bushing turning from right to left slowly pushing rotor in casing 10 11 Place packing retainer washer in bottom of packing chamber and pack pump with new packing Use packing suitable for liquid being pumped Install packing staggering the joints from one side of shaft to other Lubricate packing rings with oil grease or graphite to aid assembly A length of pipe will help to seat each packing ring Install packing gland capscrews and nuts Back rotor and shaft out of casing just far enough to insert packing gland through side opening of bracket over end of shaft Make sure gland is installed square and nuts are tightened evenly Tighten nuts wrench tight then back off until gland is slightly loose Coat idler pin with non detergent SAE 30 weight oil and place idler and bushing on idler pin in head If replacing with carbon graphite bushing refer to Installation of Carbon Graphite B
14. earings with compressed air Do not allow bearings to spin turn them slowly by hand Spinning bearings will damage race and balls Make sure bearings are clean then lubricate with non detergent SAE 30 weight oil and check roughness Roughness may be determined by turning outer race by hand Be sure shaft is free from nicks burrs and foreign particles that might damage bracket bushing Scradches on shaft in seal area will provide leakage paths under mechancial seal Casing can be checked for wear or damage while mounted on bracket ASSEMBLY Standard Mechanical Seal Synthetic Rubber Bellows Type Models AK4125 and AL4125 The seal used in this pump is simple to install and good performance will result if care is taken during installation The principle of the mechanical seal is contact between the rotary and stationary members There parts are lapped to a high finsh and their sealing effectiveness depends on complete contact 1 Install bracket bushing If bracket bushing has a lubrication groove install bushing with groove at 6 00 o clock position in bracket If carbon graphite refer to Installation of Carbon Graphite Bushings page 13 Coat shaft of rotor shaft assembly with non detergent SAE 30 weight oil Start end of shaft in bracket bushing turning from right to left slowly pushing rotor in casing Coat idler pin with non detergent SAE 30 weight oil and place idler and bushing on idler pin in head If replac
15. ent to approximately 002 inch end clearance for G size pump and 0015 inch for all other sizes End clearances set per Step 4 are adequate for viscosities up to 750 SSU SAE2O lube oil at room temperature Higher viscosity liquids require additional end clearances As a general guideline for viscosities between 750 and 7500 SSU heavier lube oils double the amount of end clearance indicated in Step 4 for viscosities between 13 7500 and 75 000 SSU e g resins triple the amount and for viscosities greater than 75 000 SSU e g black strap molasses use 4 times the amount For specific recommendations for check with your Viking factory 6 Tighten will only damage the threads 7 Tighten all setscrews that hold inner and outer end caps to prevent their turning in bracket 8 Rotor and shaft should turn smoothly by hand one complete revolution If rotor and shaft doesn t smoothly go back and repeat Thrust Bearing Adjustment Steps 1 thru 8 PUMP Turn Outer End Cap C C W SIZE No of Notches 8 Each small notch on outer end cap represents 001 inch end clearance FIGURE 16 INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing carbon graphite bushings extreme care must be taken to prevent breaking Carbon graphite is a brittle material and easily cracked If cracked the bushing will quickly disintegrate Using a lubricant and adding a chamfer on the bushing and the mating part wil
16. f mechanical seal rubber parts Slide rotary member lapped contact surface facing away from spring over installation sleeve on shaft until it is against spring Do not compress spring Lubricate outer diameter of mechanical seal Gring seat gasket and flush lapped seal faces with non detergent SAE 30 weight oil Press stationary seal seat in bore until back unlapped face is just inside bore Position stationary seal seat by installing seal holder and secure seal holder to machined face of bracket with seal holder plate Tighten nuts securing seal holder plate evenly so seal holder will not be distorted Remove tapered installation sleeve Slide inner bearing spacer recessed end facing rotor collar over shaft with Place pair of half round rings on shaft and slide inner bearing spacer collar over half round rings to lock them in place Refer to Figure 6 page 4 Press lip seal lip facing end of shaft in inner end cap and insert end cap through shaft end of bracket Turn end cap clockwise looking at shaft end until it engages threads End cap spanner wrench holes must be facing rotor Turn end cap with spanner wrench until it projects slightly from opening on side of bracket 16 17 18 19 20 End cap must not be turned so far that lip seal drops off end of spacer colar on shaft or end cap becomes disengaged from threads Refer to Figure 6 page 4 If this happens remove inner spacer collar half ro
17. ing carbon graphite bushing refer to Installation of Carbon Graphite Bushings page 13 Using a 010 to 015 inch head gasket install head and idler assembly on pump Pump head and casing were marked before disassembly to insure proper reassembly If not be sure idler pin which is offset in pump head is positioned toward and equal distance between port connections to allow for proper flow of liquid through pump If pump is equipped with jacketed head plate install at this time with new gasket Tighten head capscrews evenly Examine set colar to be sure there are no burrs or scratches and that setscrews are withdrawn so shaft will not be scratched when set collar is installed 12 10 11 12 13 14 15 Place seal set collar on shaft push into seal chamber so centerline of setscrew coincides with centerline of access hole on left side of bracket viewed from shaft end Refer to Figure 15 Tighten setscrews to secure set collar to shaft Slide spring over shaft into seal chamberon set collar pilot Place tapered installation sleeve on shaft Refer to Figure 10 LEFT SIDE OF PUMP ACCESS HOLE FOR TIGHTENING SETSCREWS IN SET COLLAR f SPRING ADAPTER cs MECHANICAL SEAL ROTARY MEMBER 1 4 SEAL SEAT GASKET i je SEALHOLDER SET COLLAR SEAL SEAT FIGURE 15 Apply generous amount of non detergent SAE 30 w eight oil to large diameter of shaft tapered installation sleeve and inner diameter o
18. ip seal and remove if it shows wear or damage Lip seal must be removed if bracket bushing needs to be replaced 9 Clean all parts thoroughly and examine for wear or damage Check lip seals ball bearing bushing and idler pin and replace if necessary Check all other parts for nicks burrs excessive wear and replace if necessary Wash bearings in clean solvent Blow out bearings with compressed air Do not allow bearings to spin turn them slowly by hand Spinning bearings will damage race and balls Make sure bearings are clean then lubricate with nondetergent SAE 30 weight oil and check for roughness Roughness can be determined by turning outer race by hand Be sure shaft is free from nicks burrs and foreign particles that might damage bracket bushing Scratches on shaft in seal area will provide leakage paths under mechanical seal 10 Casing can be checked for wear or damage while mounted on bracket ASSEMBLY Standard Mechanical Seal Synthetic Rubber Bellows Type The seal used in this pump is simple to install and good performance will result if care is taken during installation The principle of the mechanical seal is contact between the rotary and stationary members These parts are lapped to a high finish and their sealing effectiveness depends on complete contact Viking furnishes a number of heavy duty pumps with special mechanical seals installed in the packing end of the pump These special seals are not discu
19. knut and lockwasher from shaft There is no lockwasher on G size pump 4 Remove packing gland nuts 5 Tap shaft forward approximately 0 5 inch and remove pair of half round rings under inner bearing spacer collar There is no pair of half round rings on G H and HL size pumps 6 Carefully remove rotor bracket bushing and shaft to avoid damaging 7 Remove packing gland from side of bracket GREASE FITTING LOCATION NYLON INSET i SETSCREWS INNER Se END CAP 7 OUTER END CAP HALFROUND ANYS LOCKWASHER RINGS Sa ee rr LOCKNUT INNER ie SPACER X COLLAR Z A lia Hi aka OUTER 3 AA ray rms SPACER INNER LIP SEAL P i k i f E 3 Th 3 a B i T a pee N COLLAR pi s F i OUTER LIP BALL BY SEAL BEARING BRACKET FIGURE 6 8 Loosen setscrews Two on G H and HL size pumps four on all other sizes With a spanner wrench remove both end caps with lip seals Remove ball bearing and spacer collars Refer to Figure 6 9 Remove packing and packing retainer washer 10 Clean all parts thoroughly and examine for wear and damage Check lip seals ball bearing bushings and idler pin and replace if necessary Check all other parts for nicks burrs excessive wear and replace if necessary Wash bearings in clean solvent Blow out bearings with compressed air Do not allow bearings to spin turn them slowly by hand Spinning bearings will damage race and balls Make sure bearings are cl
20. l help in installation The additional precautions listed below must be followed for proper installation 1 Apress must be used for installation 2 Becertain bushing is started straight 3 Do not stop pressing operation until bushing is in proper position starting and stopping will result in a cracked bushing 4 Check bushing for cracks after installation Carbon graphite bushings with extra interference fits are frequently furnished for high temperature operation These bushings must be installed by a shrink fit 1 Heat bracket or idler to 750 F Install cool bushings with a press If facilities are not available to reach 750 F temperature it is possible to install with 450 F temperature however the lower the temperature the greater the possibility of cracking bushing Consult factory with specific questions on high temperature applications Refer to Engineering Service Bulletin ESB 3 end clearances for viscosity or for operating temperatures above 225 fF representative or consult the inner end cap with a spanner wrench Tap spanner wrench lightly but DO NOT OVER TIGHTEN as it or Length on O D Inches PRESSURE RELIEF VALVE INSTRUCTIONS O O OO e mapa KE is WA E Taaa ea ll Ht Uiii Hi i Fa ag sao Hf il f ge tN a Ar aiii Muna LIST OF PARTS 1 Valve Cap 6 Valve Body 2 Adjusting Screw 7 Valve Spring 3 Lock Nut 8 Poppet 4 Spring Guide 9 Cap Gasket 5
21. light coat of non detergent SAE 30 weight oil must be applied to all internal pump parts Lubricate fittings and apply grease to pump shaft extension Viking suggests rotating pump shaft by hand one complete revolution every 30 days to circulate the oil SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 125 and 4125 pumps These tools are in addition to standard mechanics tools such as open end wrenches pliers screw drivers etc Most of the items can be obtained from an industrial supply house 1 Soft Headed hammer 2 Allen wrenches some mechanical seals and set collars 3 Packing hooks flexible packed pumps Small for 0 25 inch and 0 31 inch cross section packing Large for 0 38 inch and up cross section packing 4 Mechanical seal installation sleeve Viking Part No 2 751 001 900 for 0 75 inch seal G4125 Viking Part No 2 751 002 900 for 1 12 inch seal H amp HL4125 Viking Part No 2 751 003 900 for 1 44 inch seal AK LL4 125 5 Bearing locknut spanner wrench Source 471 J H Williams amp Co or equal 6 Spanner wrench adjustable pin type for use on double end caps Source 482 J H Williams amp Co or equal 7 Brass bar 8 Arbor press PACKED PUMPS CASING IDLER BALL BEARING BRACKET BUSHING IDLER PIN PACKING GLAND ROTOR HEAD VALVE BODY LIP SEAL OUTER PACKING RINGS END CAP POPPET VALVE SPRING SHAFT SPRING GUIDE LOCKNUT BON
22. n shaft and push or gently drive in place in bracket Press lip seal lip facing end of shaft in outer end cap and insert end cap in bracket Turn end cap in bracket until it is tight against bearing Refer to Figure 6 page 4 Put lockwasher and locknut on shaft Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Tighten locknut and bend one tang of lockwasher into slot of locknut There is no lockwasher on G size pumps 12 Adjust pump end clearance Refer to Thrust Bearing Adjustment page 13 13 Lubricate all grease fittings with multi purpose grease NLGI 2 DANGER BEFORE STARTING PUMP BE SURE ALL DRIVE EQUIPMENT GUARDS ARE IN PLACE FAILURE TO PROPERLY MOUNT GUARDS MAY RESULT IN SERIOUS INJURY OR DEATH MECHANICAL SEAL PUMPS INNER END CAP CASING ROTOR BRACKET BUSHING LIP SEAL INNER END CAP IDLER PIN SHAFT VALVE BODY OUTER END CAP POPPET LOCKNUT VALVE SPRING LOCKWASHER BONNET GASKET LIP SEAL OUTER END CAP BALL BEARING Ea a 1AN SETSCREW JO ia _ Mss PIPE PLUG HEAD GASKET SPRING GUIDE BONNET CAP GASKET VALVE GASKET LIPSEAL ADJUSTING SCREW LOCKNUT VALVE CAP BRACKET GREASE FITTING BRACKET GASKET FIGURE 7 Cutaway View of KK 4125 with Callouts Exploded View for Models G4125 H4125 HL4125 K4125 KK4125 L4125 LQ4125 and LL4125 Model KK4125 sh
23. nate to the standard mechanical seal synthetic rubber bellows type These seals are setscrew driven and the stationary seats have anti rotation pins which mate with slots in the end of the bracket bushing 1 5 Install bracket bushing If bracket bushing has a lubrication groove install bushing with groove at 6 00 o clock position in bracket If carbon graphite refer to Installation of Carbon Graphite Bushings page 13 Install lip seal in bracket Clean rotor hub and bracket seal housing bore Refer to Figure 12 Make sure both are free from dirt and grit Coat outer diameter of seal seat gasket and inner diameter of seal housing bore with nondetergent SAE 30 weight oil ANTEROTATION PINS ALIGNED WITH SLOTS IN BUSHING INSTALLATION TOOL a we ce Lf ZI ee COAT WITH LIGHT OIL BEFORE ASSEMBLY BRACKET SEAL HOUSING BORE WITH SEAL SEAT INSTALLED NOTE SPECIAL INSTALLATION TOOL USED FOR FACTORY ASSEMBLY FIGURE 12 Start seal seat in seal housing bore Make sure seat anti rotation pins are aligned to engage slots in end of bracket bushing Refer to Figure 12 Using a cardboard disc to protect lapped face of seal seat press seal seat assembly to bottom of seal housing bore using a piece of wood An arbor press can also be used to install the seal seat Seal seat must be started square and carefully pressed to bottom of seal housing bore K size pumps require a 0 25 inch spacer between seal and rotor hub
24. own STEELT F J li pI 13 NAME OF PART a wareorpanr Tew 9 End Cap Inner 17 Bracket Gasket 25 Head and Idler Pin 18 Casing 26 Gasket for Jacketed Head Plate Locknut Lockwasher Not G 10 Lip Seal for Seal Chamber Jacketed Head Plate Capscrew for Head Relief Valve Gasket 6 Bali Bearing 14 Capsorewtor Bracket 22 Idler Bushing 30 Capscrew for Valve internal Relief Valve 8 Ring Half Round Not G H HL 16 MechanicalSeal 24 Idler Pin For Disassembly and Assembly of AK 4125 and AL 4125 see page 11 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 CHAMBER HAS BEEN COMPLETELY VENTED THROUGH SUCTION OR DISCHARGE LINES OR OTHER APPROPRIATE OPENINGS OR CONNECTIONS 2 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 3 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 1 Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump h
25. panner wrench until it projects slightly from opening on side of bracket End cap must not be turned so far that lip seal drops off end of spacer collar on shaft or end cap becomes disengaged from threads Refer to Figure 6 page 4 If this happens remove inner spacer collar half round rings and end cap and start over at Step 11 Pack ball bearing with multi purpose grease NLGI 2 Place on steft and push or gently drive in place in bracket Press lip seal lip facing end of shaft in outer end cap and insert end cap in bracket Turn end cap in bracket until it is tight against bearing Refer to Figure 6 page 4 Put lockwasher and locknut on shaft Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Tighten locknut and bend one tang of lockwasher into slot of locknut There is no lockwasher on G size pump Adjust pump end clearance Refer to Thrust Bearing Adjustment page 13 Lubricate the grease fitting over the seal chamber with petroleum jelly petrolatum Vasoline or other similar low melting point lubricant Lubricate all other grease fittings with multi purpose greas e NLGI 2 DANGER BEFORE STARTING PUMP BE SURE ALL DRIVE EQUIPMENT GUARDS ARE IN PLACE FAILURE TO PROPERLY MOUNT GUARDS MAY RESULT IN SERIOUS INJURY OR DEATH ASSEMBLY Optional Mechanical Seal Teflon Fitted Type The seal type shown in Figures 12 13 and 14 can be installed as an alter
26. ssed in TSM141 1 Information is available by contacting the factory When requesting special seal information be sure to give pump model number and serial number 1 Install bracket bushing If bracket bushing has a lubrication groove install bushing with groove at 6 00 o clock position in bracket If carbon graphite refer to Installation of Carbon Graphite Bushings page 13 2 Install lip seal in bracket Refer to Figure 8 i LIP SEAL FOR SEAL CHAMBER 7 TAPERED INSTALLATION SLEEVE BRACKET BUSHING BRACKET FIGURE 8 Prior to installing rotating portion of mechanical seal prepare and organize rotor shaft head and idler assemblies and appropriate gaskets for quick assembly Once rotating portion of mechanical seal is installed on rotor shaft it is necessary to assemble parts as quickly as possible to insure that seal does not stick to shaft in wrong axial position The seal should be expected to stick to the shaft after several minutes setting time Never touch sealing faces with anything except clean hands or clean cloth Minute particles can scratch the seal faces and cause leakage 3 Coat idler pin with non detergent SAE 30 weight oil and place idler and bushing on idler pin in head If replacing a carbon graphite bushing refer to Installation of Carbon Graphite Bushings page 13 4 Clean rotor hub and bracket seal housing bore Make sure both are free from dirt and grit Coat outer diameter of seal seat
27. stalled either next to rotor hub or in an altered stuffing box Extra care must be taken in repair of pumps with mechanicd seals Read and follow all special information supplied with pump MAINTENANCE Series 125 and 4125 pumps are designed for long trouble free service life under a wide variety of application conditions with a minimum of maintenance The points listed below will help provide long service life LUBRICATION External lubrication must be applied slowly with a hand gun to all lubrication fittings every 500 hours of operation with multi purpose grease NLGI 2 Do not over grease Applications involving very high or low temperatures will require other types of lubrication Refer to Engineering Service Bulletin ESB515 Consult factory with specific lubrication questions PACKING ADJUSTMENT New packed pumps require initial packing adjustment to control leakage as packing runs in Make initial adjustments carefully and do not over tighten packing gland After initial adjustment inspection will reveal need for packing gland adjustment or packing replacement Refer to instructions under Disassembly page 4 and Assembly page 4 regarding repacking pump CLEANING PUMP Keep pump as clean as possible This will facilitate inspection adjustment and repair work and help prevent overlooking a dirt covered grease fitting STORAGE f pump is to be stored or not used for six months or more pump must be drained and a
28. to properly position seal on shaft Place tapered installation sleeve furnished with H HL K KK L LQ and LL gze replacement mechanical seals on shaft Refer to Figure 13 Coat inner diameter of seal rotary member tapered installation sleeve and the shaft with a generous quantity of non detergent SAE 30 weight oil Place rotary member on shaft over sleeve and gainst hub of rotor Refer to Figure 14 TAPERED INSTALLATION SLEEVE Fa L MECHANICAL SEAL SHAFT ROTARY MEMBER FIGURE 13 ROTOR HUB J MECHANICAL SEAL ROTARY MEMBER SHAFT 0 25 INCH THICK SPACER COLLAR USED HERE ON kK SIZE PUMP FIGURE 14 Some Teflon seals are equipped with holding clips which compress the seal springs Remove holding clips to release springs after seal is installed on shaft Tighten all drive setscrews securely to shaft AT THIS POINT FINISH ASSEMBLY PROCEDURES STARTING AT STEP 9 PAGE 8 STANDARD MECHANICAL SEAL 10 Exploded View for Models AK41 25 and AL41 25 Model AK41 25 shown a ra a ht L j lt Thoo t ICH OO Ci i e a a 2 Lockwasher 11 Seal Holder Capscrew 20 Bracket Bushing 2 Head andiderPn Bearing Spacer Collar Outer 14 Mechanical Seal Pipe Plug Capscrew for Relief Valve Lip Seal for End Cap 13 Seal Holder Relief Valve Gasket 6 Ball Bearing 15 Set Collar with Setscrews Rotor and Shaft Internal Relief Valve BEFORE OPENING ANY VIKING PUMP LIQUID CHAMBER PUMPING CHAMB
29. und rings and end cap and start over at Step 15 Pack ball bearing with multi purpose grease NLGI 2 Place on shaft and push or gently drive in place in bracket Press lip seal lip facing end of shaft in outer end cap and insert end cap in bracket Turn end cap in bracket until it is tight against bearing Refer to Figure 6 page 4 Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Put lockwasher and locknut on shaft tighten and bend one tang of lockwasher into slot of locknult Adjust pump end clearance Refer to Thrust Bearing Adjustment below Lubricate all grease fittings with multi purpose grease NLGI 2 DANGER BEFORE STARTING PUMP BE SURE ALL DRIVE EQUIPMENT GUARDS ARE IN PLACE FAILURE TO PROPERLY MOUNT GUARDS MAY RESULT IN SERIOUS INJURY OR DEATH THRUST BEARING ADJUSTMENT 1 Loosen setscrews over outer and inner end caps Two for G H and HL size pumps four for all other sizes Turn inner end cap clockwise viewed from shaft end until it projects slightly from bracket exposing approximately three threads Turn outer end cap clockwise until rotor is tight against head and rotor shaft cannot be turned Make a reference mark on bracket end opposite a notch on outer end cap There are no notches on G size pump Back off outer end cap required number of notches Refer to Figure 16 Each 0 25 inch travel on circumference of end cap is equival
30. ushings page 13 Using a 010 to 015 inch head gasket install head and idler assembly on pump Pump head and casing were marked before disassembly to insure proper reassembly If not be sure idler pin which is offset in pump head is positioned toward and equal distance between port connections to allow for proper flow of liquid through pump If pump is equipped with jacketed head plate install at this time along with new gasket Tighten head capscrews evenly Slide inner spacer collar over shaft with recessed end facing rotor G H and HL size bearing spacer collars are not recessed Place pair of half round rings on shaft and slide inner bearing spacer collar over half round rings to lock them in place There is no pair of half round rings on G H and HL size pumps Refer to Figure 6 page 4 Press lip seal lip facing end of shaft in inner end ap and insert end cap through shaft end of bracket Turn end cap clockwise looking at shaft end until it engages threads End cap spanner wrench holes must be facing rotor Turn end cap with spanner wrench until it projects slightly from opening on side of bracket End cap must not be turned so far that lip seal drops off end of spacer collar on shaft or end cap becomes disengaged from threads Refer to Figure 6 page 4 If this happens remove inner spacer collar half round rings and end cap and start over at Step 7 Pack ball bearing with multi purpose grease NLGI 2 Place o
31. weight oll Start end of shaft in bracket bushing and turn from tight to left slowly pushing until the ends of the rotor teeth are just below the face of the casing Leave the rotor in this position Withdrawal of rotor and shaft may displace the carbon seal rotating face and result in damage to the seal 10 Using a 010 to 015 inch head gasket install head and idler assembly on pump Pump head and casing were marked before disassembly to insure proper reassembly If not be sure idler pin which is offset in pump head is positioned toward and equal distance between port connections to allow for proper flow of liquid through pump 11 12 13 14 15 16 17 If pump is equipped with jacketed head plate install at this time along with new gasket Tighten head capscrews evenly Remove tapered installation sleeve from the shaft Slide inner spacer collar over shaft with recessed end facing rotor G H and HL size bearing spacer collars are not recessed Place pair of half round rings on shaft and slide inner bearing spacer collar over half round rings to lock them in place There is no pair of half round rings on G H and HL size pumps Refer to Figure 6 page 4 Press lip seal lip facing end of shaft in inner end cap and insert end cap through shaft end of bracket Turn end cap clockwise looking at shaft end until it engages threads End cap spanner wrench holes must be facing rotor Turn end cap with s
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