Series 4195-G
Contents
1. 20 ornnes 3 ens captor Bearna rowna 12 comas a dem Ca Coser Bearna Housing t3 _ RetntocankReietvave 22 cese s eareearno ouen 4 Capsrensorvave Coverite 23 sem s Bearing Housing win Someone 45 Peto 2 Gomes tr en 7r ecaro seer oe Rowrana Shak 25 rere yE Ce emeente Sr menasa S s Bearing Reanerwasher 18 uemene S SECTION TSM 442 ISSUE C PAGE 4 OF 10 DISASSEMBLY DANGER Before disassembling a pump or removing it from the line be sure the pump and system are free of LP Gas As an extra precaution protective clothing for face and body should be used when doing this work 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 these2. shaft 6 Loosen the two 2 setscrews in the end of the bearing housing turn the bearing housing counter clockwise and remove from the casing Remove the snap ring from the bearing housing on GG HJ and HL size pumps and the double row ball bearing can be removed On the AS AK and AL size pumps you must loosen the setscrews in the outer ring of the bearing housing and remove the bearing housing end cap closure and bearing collar Use a spanner wrench to remove the end cap Wash the bearing thoroughly and examine If there is any evidence of wear or damage a new bearing should be used Remove the snap ring and casing ball bearing in the GG HJ and HL size pumps Remove the bearing spacer and casing ball bearing in the AS AK and AL size pumps The bearing retainer washer located between the casing bearing and seal seat can now be removed if it did not stay on the rotor shaft when the shaft was removed The seal seat or stationary part of the seal can now be removed from the casing The casing should be examined for wear particularly at the seal area between the port openings 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 advisable to also install a new head and idler SECTION TSM 442 ISSUE C PAGE 5 OF 10 ASSEMBLY 1 Installing New Seal The seal is simple to install and good performance will result if care is tak
3. Electronic copies of the most current TSM issue can be found on the Viking Pump website at www vikingpump com TECHNICAL SERVICE MANUAL oron isa VIKING LP GAS PUMPS pace 10F 10 SERIES 4195 G SIZES GG AL CONTENTS Introduction 2 204 1 Safety Information lll 2 Special Information css 3 Maintenance lll sn 3 Disassembly 2 rens 5 Assembly lvo y Ros RRO Kae boa XX x Re 6 Thrust Bearing Adjustment 6 Pressure Relief Valve Instructions 6 Supplementary Section 8 Warranty x bi pace eas Soka ee ae OXOROEDE E 10 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 model number and serial number of the pump when ordering repair parts The unmounted pump or pump unit model number and serial number can be found on a nameplate attached to the pump or base MODEL NUMBER CHART UNMOUNTED PUMPS UNITS GG 4195 G HJ 4195 G Units are designated by the unmounted pump model numbers HL 4195 G followed by a letter s indicating AS 4195 G drive style AK 4195 G AL 4195 G FIGURE 2 AS AK AL 4195 G UNMOUNTED PUMP D Direct Drive CAUTION This manual deals exclusively with the 4195 G
4. SEMBLY Lock Nut Poppet Spring Guide Cap Gasket Follow the procedure outlined under Disassembly When ordering springs be sure to give the pressure setting desired If valve is removed for repairs be sure to replace in same position The valve cap should point towards the Bonnet Bonnet Gasket suction port DISASSEMBLY IMPORTANT In ordering parts for relief valve on head always be sure DANGER to give Model and Serial Number of pump as it appears on EN nameplate and the name of the part wanted When ordering Before opening any Viking pump liquid springs be sure to give the pressure setting desired 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 SECTION TSM 442 ISSUE C PAGE 7 OF 10 SUPPLEMENTARY SECTION INTRODUCTION Your Viking Model GG 4195G
5. Series LP Gas The 4195 G series is a UL listed pump Any pumps Refer to Figures 1 thru 10 for general configuration changes or repairs to the pump will void and nomenclature used in this manual the UL listing To maintain the UL listing the pump will need to be replaced with a new pump or repaired and retested at the factory If the UL listing is no longer required refer to TSM 144 for repair instructions These can be obtained from your authorized Viking Pump distributor CORPORATION VIKING PUMP INC eA 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 442 A 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 vented through the suction or discharge lines or other appropriate op
6. djustment and repair work and help prevent omission of lubrication to fittings covered or hidden with dirt 3 STORAGE If the 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 SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 4195 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 Allen Wrenches some mechanical seals and set collars 3 Mechanical seal installation sleeve Bearing locknut spanner wrench Source 471 J H Williams amp Co or equal Brass Bar Arbor Press SECTION TSM 442 ISSUE C PAGE 3 OF 10 FIGURE 3 Exploded View GG HJ HL 4195 G Pumps afo 15 iren L3 sempus 3 Peres fope 3 at Bearno Ouen La snap Rng erste RoworanaShat 38 GantetorRetervave s Bearna Housing win Sasous 42 ier Bushing 9 Retumcto Tenk Rerervane Le soaring ten s me 72 apr for Va Cr suene me orrasa f TIT Geo FIGURE 4 Exploded View AS AK AL 4195 G Pumps Dre 9 mm 9 2 serra sparco oRng vane Gusiet
7. en in its installation NOTE Never touch the sealing faces with anything except the fingers or a clean cloth Clean the rotor hub shaft and seal seat housing in the casing making sure they are clean and free from dirt and grit Coat the outside diameter of the seal seat and the inside diameter of the seal seat and the inside diameter of the seal housing bore with light oil With thumb and forefinger push the seal seat into place in the casing Place the tapered sleeve furnished with replacement seals on the shaft as far as it will go Thin end must be toward end of shaft See Figure 5 Coat the inside of the rotary member and the outside of the tapered sleeve with light oil Be sure the shaft is free of nicks and burrs Place the spring and rotary member on the shaft spring first over the sleeve and against the hub of the rotor Remove the tapered sleeve 2 Flush the sealing faces of both the rotary member and seal seat with light oil and install rotor and shaft Push the rotor and shaft into the casing slowly until the ends of the rotor teeth are just beyond the face of the casing MECHANICAL SEAL ROTARY MEMBER SPRING See i TAPERED SLEEVE COAT WITH LIGHT OIL BEFORE ASSEMBLY FIGURE 5 3 Place the idler on the idler pin and the O ring head gasket on the head Place the head assembly on the pump and tighten the capscrews evenly and securely The seal is now automatically compressed to its pr
8. enings 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 pump s rated pressure speed 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 C PAGE 2 OF 10 Danger Failure to follow the indicated instruction may result in serious injury Warning In addition to possible serious injury or death failure to follow the indicated instruction may cau
9. g pumps are positive placement pumps and must be provided with some sort of pressure protection Series 4195 G pumps are available with a return to tank or standard relief valve as options 2 If pump rotation is to be reversed during operation pressure protection must be provided on both sides of pump 3 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 4 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 TSM000 and Engineering Service Bulletin ESB 31 SPECIAL MECHANICAL SEALS Extra care should be taken in repair of these pumps Be sure to read and follow all special instructions supplied with your pump MAINTENANCE Model 4195 pumps are designed for long trouble free life under a wide variety of application conditions with a minimum of maintenance however the following should be considered 1 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 Reassembly of the pump for information regarding this procedure 2 CLEANING THE PUMP It is good practice to keep the pump as clean as possible This will facilitate inspection a
10. he 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 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 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 ROTATION Viking pumps operate equally well in a clockwise or counterclockwise rotation When rotation changes the suction and discharge is reversed PRESSURE RELIEF VALVES 1 Vikin
11. hookups should be made by a qualified electrician and must meet all applicable local and national standards for installations handling LP Gas FIGURE 10 TYPICAL INSTALLATION OF VIKING GG 4195D G LP GAS PUMP UNIT SHOWING RECOMMENDED EQUIPMENT AND LOCATION Excess Flow Valve 1 25 Fittings Shut Off Valve Full opening type and pipe Strainer 40 mesh optional connection Hose 1 Maximum length 3 feet Filler Hose 75 Minimum with shut off valve and filler connection 15ft Maximum Return Line 0 50 Minimum from by pass Valve Distance between bottom of tank and pump port centerline should be at least 12 inches one foot More vertical distance will help pump operate better and last longer Hydrostatic Relief should be installed in pump inlet port or in inlet piping SECTION TSM 442 ISSUE C PAGE 9 OF 10 TECHNICAL SERVICE MANUAL on issu VIKING LP GAS PUMPS pace 10 OF 10 SERIES 4195 G SIZES GG AL ISSUE C VIKING PUMP IBEX 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 The warranty period for Universal Seal series pumps ONLY Universal Seal models listed below is three 3 years from date of startup provided that in no event shall this warranty ex
12. oper working length 4 Packthe single row ball bearing with grease and install in the casing Install the snap ring in GG HJ and HL pumps NOTE The AS AK and AL pumps do not have a snap ring but the bearing retainer washer must be assembled over the end of the shaft before the bearing is assembled 5 Place the bearing spacer over the shaft and against the single row ball bearing in the casing AS AK and AL size pumps 6 Install the snap ring in the groove in the shaft on the HJ or HL size pumps SECTION TSM 442 ISSUE C PAGE 6 OF 10 7 Pack the lubrication chamber between the casing ball bearing and the double row ball bearing in the bearing housing approximately half full with lithium base ball bearing grease 8 Packthe double row ball bearing with lithium base ball bearing grease and press into the bearing housing Install the snap ring to hold the bearing in place NOTE On AS AK and AL pumps install the lipseal in the bearing housing end cap Put the bearing spacer sleeve in the lipseal and install this in the bearing housing and tighten securely 9 Startthe bearing housing into the casing Turn by hand until tight This forces the rotor against the head Replace and tighten the locknut on the shaft Insert a piece of brass or hardwood through the port opening between the rotor teeth to keep the shaft from turning 10 Adjust the pump end clearance as follows THRUST BEARING ADJUSTMENTS Loosen the two
13. precautions are understood Failure to follow above listed precautionary measures may result in serious injury or death Remove the head capscrews Remove the head and O Ring gasket DANGER Avoid tilting the inside of the head downward as the idler may slide off the idler pin Remove idler from idler pin If the idler pin is worn the head idler pin and the idler bushing should be replaced If the idler bushing is worn it is strongly recommended that the idler and bushing be replaced This bushing can be replaced in the field but is very difficult It is a brittle material and extreme care should be taken to prevent breaking when it is being installed in the idler If it is cracked in the idler this bushing will quickly disintegrate A hydraulic press should be used to install carbon graphite bushings Be sure the bushing is started straight DO NOT STOP the pressing operation until the bushing is in the proper position Remove the locknut from the shaft A piece of brass rod or hardwood inserted in the port opening will hold the shaft from turning The rotor and shaft can now be removed from the casing The spring and rotary member of the mechanical seal will come out with the shaft NOTE On the HJ and HL size pumps the bearing housing and double row ball bearing must be removed before the snap ring in the shaft can be removed The rotor and shaft cannot be removed until the snap ring is removed from the
14. pump is a high quality pump which will give you years of service if properly installed Correct installation particularly with regard to the vertical distance between the bottom of the tank and the pump inlet port and the size of suction fittings and the size and length and the size and length of the suction hose is very important on any LP Gas pump Improper installation will result in reduced service life of your pump Figure 8 illustrates your Viking pump unit with all its features ELECTRIC MOTOR WITH UL APPROVAL FOR LP GAS PORTS SERVICE 1750 RPM 1 2 HP 4 PIPE TAP 0 50 N P T PRESSURE REQUIRED FOR 75 PSI RELIEF VALVE CONNECTION BY PASS VALVE SETTING SUCTION DISCHARGE RETURN TO TANK PRESSURE RELIEF VALVE When viewing the unit from the motor end looking toward the pump the correct pump rotation is clockwise and the suction or inlet port is on the right FIGURE 8 GG4195D G LP GAS PUMP UNIT A return to tank pressure relief valve See Figure 9 is A mounted on the head end of the pump See Figure 8 This m d valve has 0 50 NPT connection for the return line A on Figure 9 The pump will not operate satisfactorily without this return line being hooked up The cap B on Figure 9 of the pressure relief valve must always point to the suction or inlet port of the pump If the rotation of the pump shaft is reversed so that the flow through the pump is reversed then the pressure relief valve m
15. se 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 adjusting screw caps must always point towards suction side of t
16. setscrews in the bearing housing and turn counterclockwise 0 25 measured on the outside of the bearing housing of GG HJ and HL size pumps This represents approximately 002 end clearance On the AS AK and AL size pumps turn the thrust bearing assembly counterclockwise two notches which represents approximately 003 end clearance NOTE Be sure the shaft can be rotated freely If not turn the bearing housing counterclockwise until the shaft can be turned Be sure set screws are tightened securely after adjustment is made High viscosity liquids require additional end clearance The amount of end clearance depends on the viscosity of the liquid being pumped VALVE INSTRUCTIONS jen d Loz FIGURE 6 GG HJ AND HL SIZE Remove the valve cap 2 Measure and record the length of extension of the adjusting screw 3 Loosen the locknut and back out the adjusting screw until the spring pressure is released 4 Remove the bonnet spring guide spring and poppet from the valve body Clean and inspect all parts for wear or damage and replace as necessary Y ZNA oN Ai Rf 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 FIGURE 7 AS AK AND AL SIZE Valve Cap Valve Body Adjusting Screw Valve Spring AS
17. tend more than forty two 42 months from the date of shipment from Viking UNDER NO CIRCUMSTANCES SHALL VIKING BE LIABLE UNDER THIS WARRANTY OR OTHERWISE FOR SPECIAL INCIDENTAL INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST OR UNREALIZED SALES REVENUES PROFITS INCOME COST SAVINGS OR BUSINESS LOST OR UNREALIZED CONTRACTS LOSS OF GOODWILL DAMAGE TO REPUTATION LOSS OF PROPERTY LOSS OF INFORMATION OR DATA LOSS OF PRODUCTION DOWNTIME OR INCREASED COSTS IN CONNECTION WITH ANY PRODUCT EVEN IF VIKING HAS BEEN ADVISED OR PLACED ON NOTICE OF THE POSSIBILITY OF SUCH DAMAGES AND NOTWITHSTANDING THE FAILURE OF ANY ESSENTIAL PURPOSE OF ANY PRODUCT THIS WARRANTY IS AND SHALL BE VIKING S SOLE AND EXCLUSIVE WARRANTY AND SHALL BE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ALL WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE AND NON INFRINGEMENT ALL OF WHICH OTHER WARRANTIES ARE EXPRESSLY EXCLUDED See complete warranty at www vikingpump com 3 2013 Viking Pump Inc All rights reserved CORPORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA
18. ust be removed turned 180 and remounted Lv Normal setting for the pressure relief valve on the GG4195G LP Gas pump is 75 PSI when a pressure gauge in the discharge port reads 75 PSI higher than a pressure gauge in the suction port all of the liquid will be flowing through the pressure relief valve back to the tank Higher pressure relief FIGURE 9 valve settings are not encouraged since they reduce pump RETURN TO TANK PRESSURE RELIEF VALVE life do not significantly speed up the transfer or filling rate GG HJ AND HL SIZE and often require a larger motor SECTION TSM 442 ISSUE C PAGE 8 OF 10 INSTALLATION LOCATING THE PUMP The pump should be mounted on a level surface A flat concrete slab serves very well as a foundation Make sure that there is a 12 or more vertical distance between the bottom of the tank and the pump inlet port centerline The greater the vertical distance between the bottom of the tank and the pump inlet the better the pump will perform and the longer it will last EQUIPMENT PIPING AND HOSE All equipment plus the piping fittings hose etc must be approved for use with LP Gas The equipment and installation must meet local standards as well as those of the National Fire Protection Association NFPA Standard No 58 All threaded connections should be coated with a thread sealing compound approved for LP Gas service ELECTRICAL CONNECTIONS All electrical
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