I&O Manual - GlobalGear® Series Pumps
Contents
1. specifications The orifice plug should be removed from the GG250 and smaller pumps if the viscosity of the application is greater than 7500 SSU 1650 CST Suction Port Internal Flush Holes J 1 4 NPT Plugs l Orifice LLL I LLL L 2 ZZ B Figure 4 Internal Seal Vent Slide the drive module into the housing and assemble with bolts that attach the bracket to the housing Install New Cover and Idler Gear See Table 4 for proper torque specifications Place idler assembly on cover once the idler is on the cover ensure that it rotates freely Install Cover and Idler Assembly Place the gasket on the cover Tilt the top of the cover away from the pump until the crescent can be fitted into the rotor D then rotate the idler until its teeth mesh with the rotor teeth Assemble with cover bolts If required install relief valve to the housing or cover Prior to reinstalling the relief valve back onto the pump housing or cover ensure that the valve is clear of any foreign material and that the flow ports are unobstructed Place the valve gasket on the housing or cover Assemble the valve on the pump housing or cover with valve screws Make certain the adjusting screw of the valve points towards the suction port Page 11 of 28 CAUTION The adjusting screw of the valve must point towar2. Material of Construction Rotation Sealing Type Pos 9 Sealing Method P packing IB mechanical seal behind rotor M OB mechanical seal in stuffing box C cartridge mechanical seal Pos 10 Seal Type 0 no gland or packing A standard packing graphite PTFE B NI Resistant Type 2 Mechanical Seal C food grade packing pure PTFE E Viton mechanical seal F PTFE mechanical seal H abrasion resistant mech seal Viton L gen purp single cartridge seal lt 7 500 SSU M hard face cartridge seal N process single cartridge seal lt 75 000 SSU Q Heavy Duty Slurry Viton R Heavy Duty Slurry Chemraz T TuffSeal cartridge lip seal Viton O rings K Triple Lip PMF PTFE Viton P Hard Faces Cartridge Single Mech Seal Tungsten Carbide Silicar Viton Quench Drain Pos 11 Seal Flush 0 none 1 internal vent to suction Plan 13 Pos 12 Port Type 0 none A FNPT C ANSI 125 flanged C I only D ANSI 150 flanged E ANSI 250 flanged C I only F ANSI 300 flanged Pos 13 Port Size 0 none H 1 1 2 or 40mm l 2 or 50mm J 2 1 2 or 65mm K 3 or 80mm L 4 or 100mm N 6 or 150mm A j Sequential Port Position Special Indicator Year of Design Special Number A 56 Shaft Dimensions Bushing Pin gt Clearances Pos 14 Shaft Dimensions l Inch seal amp coupling Pos 15 Bus
3. e Remove the gland nuts and washers e Remove the gland and packing e The rotor and bracket can now be separated Pumps with single seal behind the rotor In Board Location see Figure 9 e Remove the bracket e Remove the seal head from the shaft directly behind the rotor head e Remove the in board seal gland from inside the bracket e Remove the seal seat from the in board seal gland Pumps with single seal behind the bushing Out Board Location see Figure 10 e Remove the gland nuts and washer gland and gland gasket e Remove the seal head from the shaft and seal seat from the gland e Remove the out board seal collar e Remove the pin from the shaft To do this remove the plug in the 12 NPT hole in the bracket Using a needle nose pliers or similar tool remove the locating pin from the hole in the shaft The rotor and bracket can now be separated D ad mm Pumps with cartridge seal consult the separate seal instructions provided by the seal manufacturer Page 16 of 28 Clean and Inspect Clean all parts and inspect for signs of excessive wear or scoring and replace if necessary Any signs of excessive wear between the bracket bushing and shaft may also cause housing wear This should be checked If only the bracket bushing shows signs of minor wear it should be replaced Acceptable bushing clearances are shown in Table 5 for pumps with standard clearance only O ib Carnes inch CI Table 5 Bracket Bushing C
4. e Slowly and evenly tighten the two setscrews on the outer bearing cap until there is a gap slightly larger than the distance measured in Step 3 above e Determine the proper end clearance refer to Table 6 and add that dimension to the dimension measured in Step 3 above Prepare feeler gauges or gauge blocks for the total dimension and insert between the outer bearing cap and the bearing carrier in the same position that the original dimension Step 3 was taken e Start backing off the two setscrews equally This will move the rotor towards the cover Continue this until tension is felt on the feeler gauges or gauge blocks e Once the proper end clearance has been obtained remove the feeler gauges or gauge blocks and tighten the two hex head bolts e Hand rotate the pump to ensure that it rotates freely without binding Page 22 of 28 Standard End Clearances For GlobalGear Series Pumps Pump Size Cast Iron Stainless Steel Carbon Steel GG015 GG030 GG050 6G070 GG080 GG090 GG120 GG130 GG200 GG210 GG250 GG550 0 152 0 203mm 0 152 0 203mm 0 003 0 005 inch 0 076 0 127mm 0 006 0 008 inch 0 003 0 005 inch 0 076 0 127mm _ 0 006 0 008 inch 0 005 0 007 inch 0 127 0 178mm 0 008 0 010 inch 0 203 0 254mm 0 005 0 007 inch 0 127 0 178mm 0 008 0 010 inch 0 203 0 254mm 0 005 0 007 inch 0 007 0 009 inch 0 178 0 229mm 0 013 0 015 inch 0 330 0 381mm 0 008 0 010
5. s on the GG Series of pumps can be replaced without a complete disassembly of the pump Note See Table 4 for proper torque specifications Remove the Ball Bearing Assembly e Remove the bearing lock washer and locknut e Remove the outer bearing cap hex head bolts e Remove the bearing bearing cap assembly Note f dirt or rust has gotten between the bearing carrier and the bearing cap then the bearing bearing cap assembly may be difficult to remove Remove the Seal or Packing e Remove the gland nuts and washers e Remove the gland e Remove the packing Page 12 of 28 Packin Gland awi Bearing Lock Washer Locknut A A A A A SS N Mi mi HIN H H q S E A Ball Bearing Assembly Stud Nut Washer Figure 6 Pump with Packing Pumps with single seal behind the bushing Out Board location see Figure 10 Remove the gland nuts and washers Remove the gland and gland gasket Remove the seal head from the shaft Remove the seal seat from the gland Remove the out board seal collar Remove the pin from the shaft To do this remove the plug in the 1 2 NPT hole in the bracket Using a needle nose pliers or similar tool remove the locating pin from the hole in the shaft Pumps with cartridge seal consult the separate seal instructions pr
6. ED EIA SEAL GLAND Part Name ESPANA EAS AAA Assemebly echanical Seal or A nner Bearing S T Outer Bearing ap S Cover Pin Assembl E Shaft bly Ball Bearing A AA AA A E AI a RR ae dler Bushing Bearing Carrier AAA Note Pumps with 180 ports have housings with a cast integral foot These do not include a separate foot unique part for that size Page 8 of 28 Inspection Repair Should it be necessary to remove the pump from service for periodic inspection of components and or a major repair the following steps should be taken WARNING Failure to follow these instructions could result in serious bodily injury or death Do not attempt to work on any Tuthill pump installation before completing the steps below Only authorized personnel who are familiar with the repair of mechanical products should perform the necessary repair work You must familiarize yourself with the entire contents of this manual prior to performing any work Disconnect the drive so that it cannot be started while work is being performed Review the Material Safety Data Sheet MSDS applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling Vent all pressure within the pump through the suction or discharge lines Ensure that the pump has cooled to a safe temperature prior to performing any work on the pump Pump Disassembly Partial The
7. build up within the pumping cavity which can cause serious internal damage CAP GASKET BONNET SPRING GUIDE SPRING POPPET ADJUSTING SCREW CAP JAM NUT PS BONNET GASKET BODY 7 Figure 12 Relief Valve Page 23 of 28 Disassembly of relief valve see figure 12 Note the valve position in relation to the housing and suction piping Ensure that system pressure has been relieved and that the driver has been locked out prior to doing any service work e Remove the adjusting screw cap to expose the adjusting screw e Measure and record the length of the exposed amount of the screw e Loosen the adjusting screw to relieve initial spring pressure e Remove the bonnet spring guide spring and valve poppet from the main valve housing Inspect all parts for wear or damage in particular the valve seat area Excessive wear or damage at this surface would be cause for replacement of components e Re assembly of relief valve see figure 12 Ensure all parts are clean no foreign matter is in the valve and the ports are unobstructed e Reassemble valve in the reverse manner as noted in disassembly procedure Reset the adjusting screw to the original position Pressure adjustment of relief valve The safety relief valves supplied on GG Series pumps are provided with springs that can be adjusted for various settings Factory setting on all valves is 100 PSI 6 9 bar full bypass unless another setting was specified at t
8. inch 0 203 0 254mm 0 013 0 015 inch 0 330 0 381mm 0 008 0 010 inch 0 015 0 017 inch 0 203 0 254mm 0 381 0 432 mm 0 013 0 015 inch 0 127 0 178mm 0 007 0 009 inch 0 178 0 229mm 0 008 0 010 inch 0 203 0 254mm 0 008 0 010 inch 0 203 0 254mm 0 013 0 015 inch 0 330 0 381mm 0 008 0 010 inch 0 203 0 254mm 0 330 0 381mm 0 008 0 010 inch 0 203 0 254mm 0 019 0 021 Inch 0 483 0 533mm 0 015 0 017 inch 0 381 0 432 mm Table 7 End Clearance Values for Standard Clearances Note Many Tuthill pumps are provided with non standard clearances for use with high viscosity or high temperature fluids Consult the factory for clearances of these pumps Refit Coupling and Guard If you have been able to take advantage of the modular design of this pump the complete overhaul has been accomplished without removal of the housing from the base plate or piping Thus your original coupling alignment should be intact Refit the coupling and spacer double check alignment and complete any final adjustments Safety Relief Valve Instructions Tuthill provides safety relief valves on pumps for over pressure protection only They are not intended for use as flow control devices or any other similar use CAUTION Continuous operation of the valve results in excessive heat
9. polished seal faces should not be touched during the assembly process as any minor scratch could result in leakage once in service Install the mechanical seal onto the shaft Lightly polish the shaft in order to remove any minor defects e Place the seal head on the rotor shaft A light lubricant will assist Proper location of the seal is with the back portion against the collar If the seal head has setscrews tighten them once the seal head is properly located Plug the access holes when finished with the 1 2 NPT plug Install the gland Slide the gland O ring and gland over the shaft and position it onto the studs on the bracket Install the washers and nuts and tighten Pumps with cartridge seal consult the separate seal instructions provided with the new seal Install Ball Bearing Assembly Place the inner bearing cap over the shaft Install the new ball bearing onto the shaft The bearing may have a slight press on the shaft so the bearing may have to be tapped on Ensure that it bottoms out on the shaft shoulder The bearing must be pressed on the inner race not the outer race Pressing on the outer race could damage the bearing CAUTION Do not use excessive force when pressing the bearing onto the pump shaft as it could damage the mechanical seal Install the bearing lock washer and locknut After the locknut is tightened bend one of the lock washer tabs into the locknut slot to ensure that the locknut cannot vi
10. pressure within the pump through the suction or discharge lines All Tuthill pumps contain residual hydraulic oil from the factory production test Determine if this is compatible with the fluid you are pumping Ifthe fluid is incompatible then the pump must be fully flushed prior to use If the pump is to be operated at elevated temperatures the pump should be brought up to operating temperatures gradually Rapid or sudden introduction of liquids at elevated temperatures into the cold liquid chamber of the pump could cause damage to pump externals seals or other internal parts Do not run the pump dry Failure to comply with this could cause severe damage to the internal seal bushings and or metal parts Pump needs to be Earthed separately to avoid build up of Electro Static Charge Installation For optimum pump performance the suction line must be at least as large as the corresponding pump port It should be as short as possible in order to avoid excessive pressure drops and must be airtight Locate the pump as close to the source of supply as conditions permit and if possible below the level of the liquid in the reservoir When necessary to locate the pump in a pit provisions should be made to safeguard against flooding When handling high viscosity liquids the speed of the pump must be reduced and the size of the inlet lines increased to prevent cavitation Refer to the NPSHr data for the pump The GlobalGear series of pumps GG250 and smalle
11. E aan 28 MNT eset EE precept eee cass va ec enon oa rea vied 28 OD Mionna tiossaan sedge etapa E een foresees cates ees otc 28 Page 2 of 28 Introduction The GG Series pumps have been certified to the requirements of the ATEX Directive 94 9 EC for use in Category Il Group 2 G applications Read this manual before operating or working on the GG Series pumps If additional information is required to facilitate operation or maintenance contact the authorized Tuthill distributor shown at the back of this service manual GG Series pumps have been designed and manufactured to provide years of service under normal operating conditions Illustrations used in this manual are for reference purposes only Consult the factory or an authorized Tuthill distributor for proper part identification When ordering replacement parts provide as much detail as possible to ensure correct parts are provided Details should include the full model number 18 digits serial number name of part part number if known and part material General Description The GG Series pumps use the internal gear design pumping principle see Figure 1 to perform the positive displacement pumping action desired Thus the pump has only two moving parts the rotor and the idler gear Figure 1 Internal Gear Pumping Principle Pumping action is based on a rotor idler gear and crescent shaped partition cast integral with the cover Power applied to the rotor is transmitted to the idl
12. FY Tuthill Installation and Service Instructions GlobalGear Series Pumps Excellence at work Excellence in life Table of Contents A A te Ne oe eae Eve Oe ge RTS we Fr eRe ome aT TS AN nee ERT ne 3 A ate cate eel aces a ace ee A eden ca eee 3 Modular A A a cesta sacar aaa ores 3 MLO GMT Iacocca tenet ee stat ede E i EE AUR no Baia 4 GlobalGear Model Number sa a di 5 o cess chee ates gaa ce ga cpt A ate eda ace esha ses 6 dd wrap ubsahtien ntan ntt tbat Enia ESEE ESEE lab EA ESES ESEE EnEn narran 7 PUM A R itogtttaeactarete tate ytcetanenensnenteie 7 IS io 1 A SCAM cea deraideensyoncnsed acetal eaetsnd aps jantiaetan cn teeanted lps danieencncbebsasa laeciedapeoncoeeinee tiv tuesehalindend aca doeudie 8 PA tia 9 Pump Disassembly A Ea cca eaten 9 Drive Module A 10 Drive Module Installation ud ia 11 nstall New Cover and Idler sacred etvasa atthe tatna the ides anas ais calacpeataclicladagins eslstubantsnatoitctend EEEn En n nananana 11 nline Seal A E e e a A E e Edeed 12 Pump Complete Disabled ie aia 15 Pump Complete A 17 Rebuild Drive Module Assembly cs c520 AAA oldest meine 21 Adjustment of End CIES MA IS 22 Safety Relief Valve TIVSUIUIGEICOING srs dwanec AE A van E AS 23 GlobalGear Materials of Construction so cssc2uccececssnvesdssccteedul te shchuvtastasuscacosbigsdicitated fet nE EnEn EnEn Ennni nennen 25 Ud A nll esata Sioned EnEn iii 26 A O A A a a Aa aiethadetioetasiatientdemeudes 27 A A oanoma case ESEE EEEE EEE
13. GG Series of pumps provides the ability to rebuild the internal pumping components of the pump without removing the pump housing from the base plate This is accomplished by removing the cover and idler gear from the front end of the pump and the drive module from the shaft end of the pump Remove the Cover and Idler Gear WARNING When removing the cover the idler gear will generally stay on the pin Avoid tilting the cover downward as the idler may slide off causing injury or damage Note On pumps with relief valves on the cover the cover can be removed with the relief valve still mounted onto the cover If necessary remove safety relief valve If the pump has a safety relief valve mounted on it remove it by loosening the bolts that mount itto the cover or housing Prior to removing the cover the general position should be marked in relationship to the housing Once done remove the cover bolts and the cover Remove the Cover Gasket Ifa new gasket is not available re use of the original gasket is acceptable provided it is not torn or otherwise damaged Remove the Idler from the Pin With the idler gear still on the cover check for excessive wear between The pin and bushing e The idler and cover crescent e Idler width and crescent height Any visible signs of excessive wear will require replacement of the cover pin assembly and or the idler and the bushing If only the bushing shows signs of minor wear it should be replaced A
14. Pump from the Base The pump can be removed from the base for service or it can be disassembled without disturbing the housing provided a spacer coupling was originally installed If necessary remove safety relief valve If the pump has a safety relief valve mounted on it remove it by loosening the bolts that mount it to the cover or housing Remove Pump Cover On pumps with relief valves on the cover the cover can be removed with the relief valve still mounted onto the cover Prior to removing the cover the general position should be marked in relationship to the housing Once done remove the cover bolts and the cover CAUTION When removing the cover the idler gear will generally stay on the pin Avoid tilting the cover downward as the idler may slide off causing injury or damage Remove the cover gasket and if a new gasket is not available re use of the original gasket is acceptable provided it is not torn or otherwise damaged Remove the Idler from the Pin With the idler gear still on the cover check for excessive wear between e The pin and bushing e The idler and cover crescent Idler width and crescent height Any visible signs of excessive wear will require replacement of the cover pin assembly and or the idler and the bushing If only the bushing shows signs of minor wear it should be replaced Acceptable bushing clearances are shown in Table 3 for pumps with standard clearance only Note Many Tuthill pumps are pro
15. RING Figure 9 Single Seal in In Board Location It is always recommended to replace the rotor if scoring is present on the shaft If the old one is being re used lightly polish the shaft in order to remove minor defects CAUTION The highly polished seal faces should not be touched during the assembly process as any minor scratch could result in leakage once in service Place the seal head on the rotor shaft A light lubricant will assist Proper location of the seal is with the back portion against the rotor head If the seal head has setscrews tighten them once the seal head is properly located Insert a new O ring on the OD of the in board seal gland Lightly lubricate the O ring Insert the seal seat into the in board sea the seal seat Install the in board seal gl gland bore If the seal needs an anti rotation pin make sure the pin is aligned with the slot in and into the bracket making sure the pin is aligned with the hole in the bracket Alip seal is used to keep dirt and contamination away from the bracket bushing grease If this seal is damaged it must be replaced Always position the lip seal with the lip fa cing outward This will allow old grease to be displaced through the lip seal during re greasing Pumps with single seal behind the bushi ng Out Board location See Figure 10 NOTE This must be done after the bracket is mounted onto the housing and the rotor shaft assembly has been instal
16. able use as a result of wear If performance deteriorates below acceptable levels it may be moderately improved by reducing the end clearance between rotating elements Refer to the appropriate reassembly instructions to accomplish this task Ifthis doesn t improve performance to an acceptable level then more repair work may be necessary Packing Adjustment WARNING Packing is designed to leak Therefore when pumping hazardous liquids a mechanical seal is recommended to minimize any potential source of leakage that could result in a hazardous condition Pumps with packing will require periodic adjustment To accomplish this gently amp evenly tighten packing gland nuts which will further compress the packing Do not over tighten Packing is designed to keep leakage to a slight weep Normally 2 3 drops per minute is acceptable If excessive leakage persists after complete adjustment consider re packing the stuffing box or using another packing type Lubrication Requirements Outer Bearing The standard outer bearings are maintenance free They are greased and sealed by the manufacturer Optional high temperature outer bearings must be re lubricated at least every 2000 hours or 18 0 days Bearings are designed to provide a minimum L10 life of 15 000 hours at maximum speed and pressure conditions Bracket Bushing Bracket bushings that do not have grease fittings are fully lubricated by the pumped fluid and are maintenance free Bracket
17. brate loose Loosely fit the inner and outer bearing caps to the bearing carrier using the bearing cap screws DO NOT tighten the bolts at this time The end clearances can now be set Refer to instructions on Page 22 Page 14 of 28 Refit Coupling and Guard If you have been able to take advantage of the modular design of this pump the complete overhaul has been accomplished without removal of the housing from the base plate or piping Thus your original coupling alignment should be intact Refit the coupling and spacer double check alignment and complete any final adjustments Pump Complete Disassembly Procedure WARNING Failure to follow these instructions could result in serious bodily injury or death Do not attempt to work on any Tuthill pump installation before completing the steps below Only authorized personnel who are familiar with the repair of mechanical products should perform the necessary repair work You must familiarize yourself with the entire contents of this manual prior to performing any work Disconnect the drive so that it cannot be started while work is being performed Review the Material Safety Data Sheet MSDS applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling Vent all pressure within the pump through the suction or discharge lines Ensure that the pump has cooled a safe temperature prior to performing any work on the pump Remove the
18. bushings that are provided with grease fittings must be re lubricated at least every 500 hours or 60 days Idler Bushing Idler bushings that are used with standard solid idler pins are fully lubricated by the pumped fluid and are maintenance free Idler bushings that are used with optional greasable idler pins must be re lubricated at least every 500 hours or 60 days Recommended Temperature Range Description 1200 2 t Standard Grease Mobilith AW 2 A o fu UND Wo Fe FT BS PN ww Uo e un o o o Rofo ao Y poo poo UD J WO OT NN A U9 En o NO oO Low Temp Grease Mobile Mobiletemp SHC 32 Mobile Mobilgrease FM 102 Table 2 Recommended Lubricants NO o oO High Temp Grease High Temp F gt mjoli OJo o 1 No o Food Grade Grease o 1 as RO o Note This lubrication data is only intended as a guide Some applications may have different lubrication requirements depending on actual conditions Page 7 of 28 Parts Interchangeability BEARING CARRIER BRACKET BUSHING S aN RELIEF VALVE VAIS i ASSEMBLY BEARING CAPS yx A ae Nil Ze A Body EAA E Ye IN EN ion ee pur IDLER BUSHING VW I ZN ZA ZII um WL sx A BRACKET FOOT Y SEAL ASSEMBLY HOUSING Figure 2 Pump Sie Housing NAS AAA AAA Pas Part AICC AA Assembyl Assembly i
19. cceptable bushing clearances are shown in Table 3 for pumps with standard clearance only Page 9 of 28 GG015 Table 3 Idler Bushing Clearances Note Many Tuthill pumps are provided with non standard clearances for use with high viscosity or high temperature fluids Consult the factory for clearances of these pumps Drive Module Removal Remove the drive module assembly from housing If service is being completed with the housing still mounted to the base plate piping you must first remove the spacer from the spacer coupling Adequately support the housing on the cover side so it will not fall Remove the bolts that hold the bracket to the housing Bearing Assembly z Spacer Coupling On pumps that do not have a cast integral l Y e foot remove the bolts that attach the foot to the bearing carrier The drive module assembly can then be pulled from the housing as a single unit Figure 3 Caution should be used as the drive modules can be heavy The use of a lifting device may be required Figure 3 Back Pullout V2 1 Page 10 of 28 Drive Module Installation Place the gasket on the bracket Note The standard bracket for the GlobalGear pumps provides a vent to the seal chamber from the suction port of the housing see Figure 4 Position the bracket so the vent hole lines up with the hole in the housing by the suction port See Table 4 for proper torque
20. ds the suction port The end clearances can now be set Refer to instructions on Page a7 Foot Pounds Newton Meters ETT COCOS SST 14 21 19 28 moo o 30 40 41 54 IE ESTE 15 88 Table 4a Fastener torque requirements Refit Coupling and Guard If you have been able to take advantage of the modular design of this pump the complete overhaul has been accomplished without removal of the housing from the base plate or piping Thus your original coupling alignment should be intact Refit the coupling and spacer double check alignment and complete any final adjustments In Line Seal Packing Replacement WARNING Failure to follow these instructions could result in serious bodily injury or death Do not attempt to work on any Tuthill pump installation before completing the steps below Only authorized personnel who are familiar with the repair of mechanical products should perform the necessary repair work You must familiarize yourself with the entire contents of this manual prior to performing any work Disconnect the drive so that it cannot be started while work is being performed Review the Material Safety Data Sheet MSDS applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling Vent all pressure within the pump through the suction or discharge lines Ensure that the pump has cooled to a safe temperature prior to performing any work on the pump The seals and packing
21. e the valve does not function during normal use e Tighten the locknut e Install the adjusting screw cap and gasket Page 24 of 28 GlobalGear Materials of Construction Availability Compressor bic ae 2 eae E GGc Duty cast iron Cl FASIMM8 OW o a e doing coer late jst stainless steel SS AST Mo grade CF8M r ffs ff cast steel CS ASTM A216 grade WCB a E cast iron C1 a stainless steel SS AST goe N CF8M es st cast steel CS ASTM A216 ASTM A216 grade WCB WCB Valve Block Off AISI 1018 no contact with pumpage a Plate ENC e fs fs os gt ets Cao Ji press juezas Po pop antes eS Asno S A E po fatonseeh S asia SS po gt gt mar siat tenet set as avo nde o opos sinks see ASML godeoM amo rape LS p gt are SS_ ASA desa frone Jo dened see Justin eset Ps Js demo sank see omiso gare n amore Pops tuesencaide ge Too PoP fone sos Pp Psp pp ac nadaa farog pots ps pos gt higvenp ca esbongephte popa pop genie paro Fopofofo gt Gres ps pp Gaskets graphite 316 SS o Style 3125TC wss tr Coverjacket_ ductleiron D ASTM A536 grade 80 55 06 no contact with pumpage O O a e stainless steel SS ASTM A276 grade316 Jo Page 25 of 28 A GlobalGear Temperature Limits Seal Elastomers Packing HT Opts NA a 475 F Notes 1 A pump s performance i
22. er gear with which it meshes The space between the outside diameter of the idler and the inside diameter of the rotor is sealed by the crescent As the pump starts the teeth come out of mesh increasing the volume This creates a partial vacuum drawing the liquid into the pump through the suction port The liquid fills the spaces between the teeth of the idler and the rotor and is carried past the crescent partition through the pressure side of the pump When the teeth mesh on the pressure side the liquid is forced from the spaces and out through the discharge port The materials furnished for each pump are selected to suit individual applications Modular Design The GG Series of pumps have a Modular Design concept This allows for simplified maintenance of the pump and a broad range of flexibility on the design For more information consult the GG Series Catalog or your authorized Tuthill distributor The GG Series of pumps allows for simplified repairs e Back Pullout This allows the Drive Module rotor bracket bearing carrier bearing caps assembly to be removed from the pump housing without disturbing the piping attachments This requires the use of a spacer coupling In Line Seal Replacement This allows for the replacement of the seals packings without completely disassembling the pump The GG series of pumps in the GG250 and smaller sizes have bolt on ports when furnished with a housing with a 90 porting arrangement This allows a b
23. er race Pressing on the outer race could damage the bearing Note The standard bracket for the GlobalGear pumps provides a vent to the seal chamber from the suction port of the housing See Figure 4 Position the bracket so the vent hole lines up with the hole in the housing by the suction port See Table 4 for proper torque specifications CAUTION Do not use excessive force when pressing the bearing onto the pump shaft as it could damage the mechanical seal Install the bearing lock washer and locknut After the locknut is tightened bend one of the lock washer tabs into the locknut slot to ensure that the locknut cannot vibrate loose Nut Size PumpSize Foot Pounds Newton Meters N 05 GG015 030 GG050 090 75 95 102 129 66120 210 10 6250 120 KM 12 GG550 20 150 63 203 Table 6 Fastener torque requirements Loosely fit the inner and outer bearing caps to the bearing carrier using the bearing cap screws DO NOT tighten the screws at this time Install Drive Module to Housing Place the gasket on the bracket and slide the drive module into the housing and assemble with drive module bolts Verify that the flush holes in the bracket are lined up with the appropriate hole in the housing Place idler assembly on cover and once the idler is on the cover ensure that it rotates freely Page 21 of 28 Install Cover and Idler Assembly e Place the gasket on the cover Tilt the top of the cover away from the p
24. he bushing with the chamfer Once insertion starts DO NOT STOP until the bushing is in proper position Starting and stopping can result in cracked bushings Tungsten Carbide or High Temperature Carbon Bushings Heat the bracket evenly to about 400 F 204 C Set the heated bracket on a flat surface Use a spacer block to properly locate the bushing see Figure 8 Drop the bushing into the bracket Allow the bracket to air cool to room temperature WARNING Wear heat resistant gloves when handling hot components BRACKET BUSHING Y A 7 SPACER A 7 PORNO OPORTO ROR RIO ROP KROSS KOI KROL ROI ROL OPK ROK ROI KR SRO OPK ROI COR EAS LR ROR OI ROKR OIL ROKR OK SOR OLESEN IR INNO SIRI LEI ES IRON BRACKET S S BRACKET Figure 8 Bracket Bushings Install Packing or Seal For pumps with packing it is always good practice to install new packing during a complete rebuild New packing sets are available from an authorized Tuthill distributor Install and seat each ring into the bracket stuffing box and stagger cut joints from one side of the shaft to the other Loosely install the gland using the gland studs nuts and washers The packing will be adjusted on site Pumps with single seal behind the rotor In Board location See Figure 9 Page 18 of 28 BRACKET ACCESS H OLE O O O 7 de LIP SEAL MECHANICAL SEAL INNER GLAND O
25. hings amp Pin A bronze idler amp bracket C carbon idler bronze bracket D carbon idler amp bracket E hi temp carbon idler amp bracket G T C idler with T C pin bronze bracket l T C idler amp bracket with T C pin amp hardened shaft Pos 16 Tutriding 0 none 1 Tutrided rotor head idler cover 2 Tutrided rotor head idler cover housing Pos 17 Jackets 0 none 1 cover only 2 bracket only 3 cover and bracket Pos 18 Clearances 0 standard lt 7 500 SSU 100 to 200 F A 7 500 to 75 000 SSU 200 to 300 F B 75 000 to 750 000 SSU G lt 7 500 SSU 300 F to 450 F see note H 450 F to 550 F see note J Chocolate Clearance Mods Include Class B Clearance Bronze Bushings Root Drilled Idler amp Drilled Rotor Head Note Pumps with G or H in this position include hi temp package paint bearing amp gaskets Legend E NOT AVAILABLE ON ALL SIZES C I Cast Iron T C Tungsten Carbide Page 5 of 28 WARNING Failure to follow these instructions could result in serious bodily injury or death Do not attempt to work on any Tuthill pump installation before completing the steps below Disconnect the drive so that it cannot be started while work is being performed Review the Material Safety Data Sheet MSDS applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling Vent all
26. ime of order This setting will vary depending on liquid viscosity and pump speed If it must be changed from this factory setting due to your operating conditions the following procedure is used Place a pressure gauge on the pump discharge line as close as possible to the pump in order to obtain accurate readings There must be no restrictions between the gauge and pump The pump housing has a tapped opening in the port area that is the best location for this gauge e Remove the adjusting screw cap and gasket to expose the adjusting screw e Loosen the lock nut Start the pump running e Slowly restrict the discharge line while observing the pressure gauge e Stop immediately if the pressure rises above a safe level With the discharge line fully closed the gauge will read the full bypass pressure setting for the current speed and viscosity Do not leave the discharge line closed for a long time since the fluid temperature will rise rapidly Adjust the valve adjusting screw to obtain the desired full bypass setting Tighten the screw to increase the setting and loosen it to reduce the setting Once set reopen the discharge line This setting should be 15 25 above normal operating pressure presented by the system to ensure the valve does not operate during normal use CAUTION If there is some other flow control device present in the system that will vary the system pressure the relief valve setting should be set above this pressure to ensur
27. in section B may also be used On idlers that use bronze bushings there is a hole through the root diameter of one of the teeth Use this hole to drill a hole through the bronze bushing Wear heat resistant gloves when handling hot components Page 17 of 28 Tungsten Carbide or High Temperature Carbon Bushings Heat the idler gear evenly to about 400 F 204 C Set the heated idler gear on a flat surface Drop the bushing into the idler gear making certain that the bushing is flush to slightly below the face of the idler Ensure that the bushing does not protrude beyond the surface of the idler on both faces Some sizes of idler gears use two bushings If this is the case install a bushing from each side making sure that the bushings do not protrude beyond the surface of the idler on either face Allow the idler to air cool to room temperature Insert New Bracket Bushing if necessary With bronze or standard carbon bushings insert the new bushing with the assistance of a hand arbor press Always install the bushing from the chamfered end of the bracket On brackets that use bronze bushings there is a hole through the bracket above the bushing Use this hole to drill a hole through the bronze bushing CAUTION Special care must be taken during the insertion of carbon bushings Ensure that the bushing diameter and idler bore are parallel as any misalignment during insertion may cause cracks The bushing should be installed using the side of t
28. learances Note Many Tuthill pumps are provided with non standard clearances for use with high viscosity or high temperature fluids Consult the factory for clearances of these pumps Tuthill quality replacement parts are available through your authorized Tuthill distributor Use of parts not manufactured by Tuthill may void your warranty Pump Complete Assembly Procedure See Table 4 for proper torque specifications Prior to reassembly ensure that all items are cleaned thoroughly and free of any metal burrs Insert new idler bushing if necessary Bronze or Standard Carbon Bushings Insert the new bushing with the assistance of a hand arbor press The bushing should be flush to slightly below the face of the idler Ensure that the bushing does not protrude beyond the surface of the idler on both faces Some sizes of idler gears use two bushings If this is the case install a bushing from each side making sure that the bushings do not protrude beyond the surface of the idler on either face CAUTION Special care must be taken during the insertion of carbon bushings Ensure that the bushing diameter and idler bore are parallel as any misalignment during insertion may cause cracks The bushing should be installed using the side of the bushing with the chamfer Once insertion starts DO NOT STOP until the bushing is in proper position Starting and stopping can result in cracked bushings If an oven is available the method described below
29. led Page 19 of 28 BRACKET ACCESS HOLE MECHANICAL SEAL COLLAR Figure 10 Single Seal in Out Board Location It is always recommended to replace the rotor if scoring is present on the shaft If the old one is being re used lightly polish the shaft in order to remove minor defects PIN Install the Locating Collar see figure 7 Using a needle nose pliers or similar tool install the locating pin by inserting it through the hole in the bracket into the hole in the shaft Position the collar so the side with the slot for the locating pin is towards the housing Slide the collar over the shaft until it engages with the locating pin Install the Stationary Seat into the Gland see figure 7 CAUTION The highly polished seal faces should not be touched during the assembly process as any minor scratch could result in leakage once in service Lightly lubricate the O ring on the stationary seat and then press the seat into the gland If the gland has an anti rotation pin make sure the pin is aligned with the slot in the seal seat Install the Mechanical Seal onto the Shaft Lightly polish the shaft in order to remove any minor defects Place the seal head on the rotor shaft A light lubricant will assist Proper location of the seal is with the back portion against the collar If the seal head has setscrews tighten them once the seal head is properly located Plug the access holes when fini
30. ly installed permitting air pocket to form in the pump e Increased clearances or wear in the pump will sometimes cause the pump to deliver an insufficient supply of liquid This may be corrected by reducing the thickness of the cover gaskets A folded gasket or a slight amount of dirt can exaggerate the problem and cause leakage e Refer to Assembly Procedure section for minimum end clearances Pump works spasmadically e Leaky suction lines e Suction conditions vary e Air or vapor in liquid Problem Excessive power draw e Pressure too high e Liquid more viscous than originally expected e Suction or discharge lines obstructed e Insufficient horsepower Mechanical defects Drive shaft and pump are misaligned e Pump is binding due to insufficient end clearance e Pump shaft is bent e Misalignment within pump due to bad piping or poor installation causing strain or distortion Pump is noisy e Pump is cavitating due to inadequate suction conditions e Misalignment of coupling Coupling set too close to pump e Vibration of pump due to worn or bent shaft e Air leaks on suction side of pump or air entrainment in fluid Pump leaks Bolts need tightening allowing gaskets or O rings to leak e Gaskets or O rings are damaged No fluid is delivered e Power is not on e Net positive suction head available NPSHa is lower than required for the vapor pressure of the liquid pumped e You should calc
31. o pump failure Because of the unpredictable nature of fluids encountered pumps are not warranted for any specific life Performance curves dimensional data and other product information is also available on the website Tuthill Pump Group Excellence at work Excellence in life USA United Kingdom China www tuthillpump com
32. ovided by the seal manufacturer Install Packing or Seal Pumps with packing Install and seat each ring into the bracket stuffing box and stagger cut joints from one side of the shaft to the other Loosely install the gland using the gland studs nuts and washers The packing will be adjusted on site Pumps with single seal behind the bushing Out Board location See Figure 10 It is always recommended to replace the rotor if scoring is present on the shaft If the old one is Bearing Assembly Spacer being re used lightly polish the shaft in order to seal fim i a remove minor defects g A Install the locating collar see Figure 7 e Using a needle nose pliers or similar tool install the locating pin by inserting it through the hole in the bracket into the hole in the shaft e Position the collar so the side with the slot for the locating pin is towards the housing e Slide the collar over the shaft until it engages with the locating pin e Install the stationary seat into the gland Lightly lubricate the O ring on the stationary seat and then press the seat into the gland If the gland has an anti rotation pin make sure the pin is aligned with the slot in the seal seat V2 1 Page 13 of 28 SY Bracket Gland O ring Gland Locating Collar Locating Pin Figure 7 CAUTION The highly
33. r provides an orifice vent to the seal chamber in the bracket from one of the housing s ports typically the suction port On applications where the viscosity is 7 500 SSU or greater the orifice plug should be removed so there is no restriction on the vent hole Pumps should be filled with liquid at installation and should never be allowed to run dry The placement of a strainer on the suction side of the pump will restrict any solids or abrasives from entering the pump which could cause internal damage Under no conditions should the pump be used to support external piping loads weight or expansion Piping and other equipment should be independently supported Piping strain can result in misalignment hot bearings worn couplings vibration etc It is important that the piping used be clean and free of chips and scales The discharge line must be designed with the maximum pressure rating of the pump in mind Excessive pressure could cause damage to your motor and or pump Ifa pressure relief valve has not been supplied with the pump some other means of pressure protection must be utilized This could include in line safety valves pressure shutdown switches or other similar devices Pumps shipped from the factory with relief valves have the relief valve set at full bypass at the factory on 150 SSU oil at our factory production test speeds Field adjustments will be required to meet the actual application requirements Refer to adjustment instruction
34. road range of flexibility for porting options in both size and configuration The GG550 has ports cast integral with the housing 90 housings can be rotated when assembled to add even more porting flexibility Page 3 of 28 GlobalGear Models material Se Max Capacity Max Pressure Weight 1500 a Cast Iron D w a n a Y a Where available cast steel has the same performance characteristics as its equivalent sized iron pump Cast Steel Table 1 GlobalGear Models Page 4 of 28 GlobalGear Model Number System For Special Pumps with a Feature not Described Below rss nse ma a 1 2 3 g amp Position 1 2 Pos 1 amp 2 Pump Series GG complete pump GD drive module Pos 3 4 amp 5 Pump Size 015 nominal 15 GPM at 1800 RPM 030 nominal 30 GPM at 1800 RPM 050 nominal 50 GPM at 1500 RPM 070 nominal 70 GPM at 1500 RPM 080 nominal 80 GPM at 1500 RPM 090 nominal 90 GPM at 1500 RPM 120 nominal 120 GPM at 1200 RPM 130 nominal 130 GPM at 1000 RPM 200 nominal 200 GPM at 1000 RPM 210 nominal 210 GPM at 800 RPM 250 nominal 200 GPM at 640 RPM 550 nominal 550 GPM at 500 RPM Pos 6 Material of Construction iron S stainless steel C cast steel Pos 7 Port Position amp Rotation SY mM ey ION C ROTATION M lt Pos 8 Relief Valve 0 none V internal
35. s on Page 32 Pumps shipped from the factory with relief valves are assembled for clockwise or counterclockwise rotation as originally specified If you want to change rotation the relief valve assembly must be removed and turned 180 degrees The adjusting screw must always point toward the suction line Every pump installation should have a good foundation Its structure should be sufficiently strong to hold the pump rigid and to absorb any strain or shock that may be encountered The installation should be leveled checked for proper piping alignment and then fastened securely The alignment should be rechecked after the pump s temperature has reached its operating temperature Direct drive through a traditional flexible coupling is recommended However do not expectthe coupling to compensate for misalignment Contact the coupling manufacturer to determine the maximum amount of misalignment that the coupling can be subjected to Never operate the pumps without all the guards in place Pumps operating with bi directional rotation must have pressure relief devices installed on both sides of the pump Prior to energizing the pump driver the pump shaft should be rotated by hand to be sure that it turns freely Tag out lock out safety procedures should be followed carefully to be sure that the pump driver cannot be energized during a hand rotation test Page 6 of 28 Simple Efficiency Improvement The efficiency of the pump may decrease after consider
36. s dependent on more than just the temperature ranges of the component materials 2 Pumps with extra clearances may have reduced flow rates when operated at lower temperatures 3 Pumps with PTFE seals also have PTFE encapsulated Viton O rings which are limited to 400 F 204 C HT Ball Bearing Gaskets and Paint HT Tungsten Carbide Bushing Cl Cast Iron Construction Cast Steel Construction HT TC Bushs SS Bronze Bushings Standard Packing PTFE Graphite o Q 5 un S Oo Ksi SS un un un aD 5 Wa Standard Carbon Bushings PTFE See Note 3 Standard Ball Bearing Gaskets and Paint Std Tungsten Carbide Bushings Cl Std Tungsten Carbide Bushing SS Clearance Class Chocolate Clearance Mods Include Class B Clearance Bronze Bushings Root Drilled Idler amp Drilled Rotor Head Page 26 of 28 Troubleshooting Capacity is too low e Air leaks in suction line amp losses are too high The suction lift is too great or the suction line is too small or too long This can be detected by installing a vacuum gauge directly at the pump suction e The maximum vacuum at the pump suction should never exceed 15 of mercury e Vaporization caused by higher vacuums will generally result in capacity drop off Redesign suction conditions e Pump speed is too slow Strainer too small or obstructed e Suction pipe or port not immersed deep enough in liquid Piping improper
37. shed with the 1 2 NPT plug Page 20 of 28 CAUTION The highly polished seal faces should not be touched during the assembly process as any minor scratch could result in leakage once in service To install the gland slide the gland o ring and gland over the shaft and position it onto the studs on the bracket Then install the washers and nuts and tighten Flush Arrangements See Figure 4 The orifice plug should be removed on GG250 pumps and smaller if the viscosity of the application is greater than 7500 SSU 1650 CST For pumps with cartridge seal consult the separate seal instructions provided with the new seal Note The standard bracket for the GlobalGear pumps provides a vent to the seal chamber from suction port of the housing See Figure 4 Position the bracket so the vent hole lines up with the hole in the housing by the suction port Rebuild Drive Module Assembly Place the rotor into the bracket and place this assembly on a flat surface so the shaft points upward The orifice plug should be removed on GG250 pumps and smaller if the viscosity of the application is greater than 7500 SSU 1650 CST Install the bearing carrier onto the bracket Place the inner bearing cap over the shaft Install the new ball bearing onto the shaft The bearing may have a slight press on the shaft so the bearing may have to be tapped on Ensure that it bottoms out on the shaft shoulder The bearing must be pressed on the inner race not the out
38. ulate NPSHa and redesign piping if necessary e Leaks in suction line or port passages can be detected by submerging pressure line from discharge side of pump into a pail of liquid where the air will be seen in the form of bubbles e Direction of shaft rotation is incorrect Relief valve setting is too low Liquid is discharging through the bypass port Note Packings are designed to leak Leakage should be at a rate that will prevent excessive heating on the bracket at the packing area Page 27 of 28 Material Returns If it becomes necessary to return a pump to the factory a Return Goods Authorization RGA must be obtained from either your local Authorized Distributor or our Alsip plant No RGA can be issued until a completed Material Safety Data Sheet MSDS has been forwarded to our Alsip plant and return of the pump approved e Tuthill pumps are precision built and must be handled with care e Pumps must be drained of all fluid and the ports plugged to prevent foreign material from getting into the pump e Pumps must be packaged securely to prevent damage while in transit Warranty Tuthill Pump Group warrants its products against defective material and workmanship for 90 days from the date of startup or one year from date of shipment from Tuthill s plant whichever comes first This warranty does not include products damaged by tampering improper installation abuse or wear Nor does it cover consequential damages or other losses due t
39. ump until the crescent can be fitted into the rotor i D e Then rotate the idler until its teeth mesh with the rotor teeth e Assemble with cover bolts and install relief valve to the housing or cover Prior to reinstalling the relief valve back onto the pump housing or cover ensure that the valve is clear of any foreign material and that the flow ports are unobstructed Place the valve gasket on the housing or cover and assemble the valve on the pump housing or cover with valve screws Make certain the adjusting screw of the valve points towards the suction port CAUTION The adjusting screw of the valve must point towards the suction port Adjustment of End Clearance pee BEARING CARRIER OUTER BEARING CAP SETSCREW Figure 11 Setting End Clearance e Loosen the two setscrews on the outer bearing cap Slowly and evenly tighten the two hex head bolts on the outer bearing cap This will slowly move the rotor towards the cover Continue this until the rotor contacts the cover This can be determined by rotating the rotor by hand Once you feel the drag between the rotor and cover stop This is zero end clearance e Measure the distance between the outer bearing cap and the bearing carrier Use appropriate feeler gauges or gauge blocks Record this dimension and then remove the feeler gauges or gauge blocks Note the position on the outer bearing cap where the dimension was taken e Loosen the two hex head bolts on the outer bearing cap
40. vided with non standard clearances for use with high viscosity or high temperature fluids Consult the factory for clearances of these pumps Page 15 of 28 Remove the Drive Module Assembly from Housing If service is being completed with the housing still mounted to the base plate piping you must first remove the spacer from the spacer coupling Adequately support the housing on the cover side so it will not fall Remove the bolts that hold the bracket to the housing On pumps that do not have a cast integral foot remove the bolts that attach the foot to the bearing carrier The drive module assembly can then be pulled from the housing as a single unit Caution should be used as the drive modules can be heavy The use of a lifting device may be required Remove the Ball Bearing Assembly e Remove the bearing lock washer and locknut e Remove the outer bearing cap hex head bolts e Remove the bearing bearing caps assembly e Remove the three bolts that hold the inner bearing cap in place and remove the inner bearing cap e Remove the outer bearing cap e Remove the bearing from the shaft e There may be a slight press fit between the shaft and bearing Use a bearing puller or other appropriate tool if required ao o om Dd mm Note If dirt or rust has gotten between the bearing carrier and the bearing cap then the bearing bearing cap assembly may be difficult to remove Remove the Seal or Packing For pumps with packing
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