TECHNICAL SERVICE MANUAL
Contents
1. free from defects in workmanship or material for a period of one 1 year from date of startup provided that in no event shall this warranty extend more than eighteen 18 months from the date of shipment from Viking If during said warranty period any products sold by Viking prove to be defective in workmanship or material under normal use and service and if such products are returned to Viking s factory at Cedar Falls lowa transportation charges prepaid and if the products are found by Viking to be defective in workmanship or material they will be replaced or repaired free of charge FOB Cedar Falls lowa Viking assumes no liability for consequential damages of any kind and the purchaser by acceptance of delivery assumes all liability for the consequences of the use or misuse of Viking products by the purchaser his employees or others Viking will assume no field expense for service or parts unless authorized by it in advance Equipment and accessories purchased by Viking from outside sources which are incorporated into any Viking product are warranted only to the extent of and by the original manufacturer s warranty or guarantee if any THIS IS VIKING S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED WHICH ARE HEREBY EXCLUDED INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE No officer or employee of IDEX Corporation or Viking Pump Inc is a2. 10 FIGURE 11 ROTOR HUB SPRING rr SHAFT FIGURE 12 Place tapered installation sleeve on shaft refer to figure 11 Sleeve is furnished with GG AS AK and AL 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 be used but grease is not recommended Place seal spring on shaft against rotor hub Refer to figure 12 Slide rotary member lapped contact surface facing away from spring over installation sleeve on shaft until it is against spring Do not compress spring Coat rotor shaft with non detergent SAE 30 weight oil Start end of shaft in bracket bushing and turn from right 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 Place O ring gasket on head and 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 or equal distance between port connections to allow for proper flow of liquid through pump MECHANICAL SEAL ROTARY MEMBER 11 12 13 14 15 16 17 18 19 Tighten head capscrews evenly If pu
3. Series 4193 amp 493 Heavy Duty Pumps i VIKING PUMP INC IDEX CORPORATION A Unit of IDEX Corporation SIZES GG AL ISSUE B FIGURE 1 GG HJ amp HL 4193 SERIES Foot Type Unmounted Pump with Flanged Ports FIGURE 2 AS AK amp AL 4193 SERIES Foot Type Unmounted Pump with Flanged Ports FIGURE 3 GG HJ amp HL 493 SERIES Unmounted Pump with Flanged Ports FIGURE 4 AS AK amp AL 493 SERIES Unmounted Pump with Flanged Ports 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 FOLLOW 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 te
4. P 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 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 ROTOR MECHANICAL SHAFT Wy 4 CASING BALL BEARINGS Refer to figure 7 amp 8 page 4 for model to be disassembled and name of parts Models 4193 amp 493 are disassembled and assembled the same The difference between these models is the casing Mark head and casing before disassembly to ensure 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 the pump Remove the head capscrew NOTE The four valve capscrews valve and gasket must be removed from the GG 4193 493 models before the six head capscrews are removed Remove head from pump Do not allow idler to fall from idler pin T
5. S AK and AL size pumps Distance in END Inches on O D of CLEARANCE Bearing Housing HJ HL 15 16 005 AS AK AL 11 4 INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing 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 will help in installation The additional precautions listed below must be followed for proper installation 1 Apress must be used for installation 2 Be sure bushing is started straight 3 Do not stop pressing operation until bushing is in proper position starting and stopping will result in cracked bushing 4 Check bushing for cracks after installation PRESSURE RELIEF VALVE INSTRUCTIONS YAOMOOO Py LZ ZZ Kye 5 tS How me ANT O OOOO BOE i HERA TIG lt S Fa X aad VALVE GG HJ and HL SIZE LIST OF PARTS Valve Cap Adjusting Screw it Be g Locknut Poppet See Cap Gasket FIGURE 13 NY Ree err EA TN SS aa 4 Pinn an A AAN ii i K WG POVP VLUUUA n Se PRE sis SSS Yo S Valve Cap Adjusting Screw Locknut Poppet Valve Body Valve Spring Spring Guide Cap Gasket Bonnet Bonnet Gasket FIGURE 14 DISASSEMBLY Mark valve and head before disassembly to ensure proper reassembly 1 Remove valve cap 2 Measu
6. TECHNICAL SERVICE MANUAL SERIES 4193 amp 493 PAGE 1 OF 9 VIKING HEAVY DUTY BRACKET MOUNTED PUMPS SECTION TSM 154 PUMP CONTENTS Introduction Special Information Special Mechanical Seals Disassembly Assembly Thrust Bearing Adjustment Installation of Carbon Graphite Bushings Pressure Relief Valve Instructions INTRODUCTION The illustrations used in this manual are for identification purposes only and cannot be used 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 NNN OO ND In the Viking model number system basic size letters are combined with series number 4193 amp 493 indicating both unmounted or mounted pump unit Model Number Chart UNMOUNTED PUMP UNITS Units are designated by the unmounted pump model numbers followed by a GG4193 letter s indicating drive style Foot Mounted HJ4193 HL4193 AS4193 D Direct Drive AK4193 AL4193 Flange Mounted M Horizontal Direct Drive IM Vertical In Line Direct Drive This manual deals only with Series 4193 amp 493 Heavy Duty Pumps Refer to figures 1thru 14 for general configuration amp nomenclature used in the manual Pump specifications and recommendations are listed in Catalog section 154
7. earing spacer sleeve in lip seal and install in bearing housing and tighten setscrews securely See figure 20 Insert a piece of brass or hard wood through port opening between rotor teeth to keep shaft from turning Start thrust bearing assembly into casing Turn by hand until tight This forces rotor against head Replace and tighten locknut on shaft Remove brass piece or hardwood from port opening Adjust pump end clearance refer to page 7 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 SECTION TSM 154 ISSUE B PAGE 6 OF 9 BEARING ADJUSTMENT THRUST See figures 9 and 10 Loosen two screws in face of thrust bearing assembly If shaft cannot be rotated freely turn thrust bearing assembly counter clockwise until shaft cannot be turned easily To set end clearance 1 While turning rotor shaft rotate thrust bearing assembly clockwise until noticeable drag occurs this is zero end clearance 2 Mark position of bearing housing with respect to the casing 3 Rotate thrust bearing assembly counter clockwise the distance listed below as measured on outside of bearing housing 4 Tighten two setscrews in face of bearing housing after adjustment is made to secure thrust bearing assembly position For viscosities above 2500 SSU add additional end clearance 0 005 for GG HJ and HL size pumps and 0 007 for A
8. eth come out of mesh is suction port PRESSURE RELIEF VALVES 1 Viking pumps are positive placement pumps and must be provided with some sort of pressure protection This may be a relief valve mounted directly on the pump an inline pressure relief valve a torque limiting device or a rupture disk 2 There are relief valve options available on these pumps Relief Valve options include an internal relief valve and a return to tank relief valve 3 If pump rotation is to be reversed during operation pressure protection must be provided on both sides of pump 4 Relief valve adjusting screw cap must always point towards suction side of pump If pump rotation is reversed remove pressure relief valve and turn end for end 5 Pressure relief valves cannot be used to control pump flow or regulate discharge pressure For additional information on pressure relief valves refer to Technical Service Manual TSMOOO and Engineering Service Bulletin ESB 31 RELIEF VALVE ADJUSTING SCREW CAP SUCTION DISCHARGE FIGURE 5 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 Series 4193 amp 493 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 CLEANING PUMP Keep pump as clean a
9. ew for Head La Capscrew for Valve Bearing Housing Ball Bearing Outer re Casing 493 Mechanical Seal Gasket for Relief Valve 18 Idler Bushing SECTION TSM 154 ISSUE B PAGE 4 OF 9 BEARING HOUSING 11 12 13 14 15 16 INNER BALL BEARING BALL BEARING OUTER ase i SNAP RING LOCKNUT eames BEARING HOUSING pia lt a THRUST BEARING ASSEMBLY GG HJ HL SIZES FIGURE 9 BEARING RETAINER WASHER BALL BEARING SETSCREW gt _ INNER BALL BEARING NYLON INSERT END CAP Y LIP SEAL BEARING SPACER l y A NW 77 ASS SD SD AAS SN tl D Len ETER n 77 T THRUST BEARING ASSEMBLY AS AK AL SIZES FIGURE 10 LOCKNUT SETSCREW The rotor shaft can now be removed by tapping on end of shaft with a lead hammer or if using a regular hammer use a piece of hardwood between shaft and hammer The spring and rotary member of the seal will come out with rotor and shaft Remove inner snap ring and single row ball bearing from casing See figure 9 The AS AK amp AL size pumps do not have this snap ring Remove bearing retainer washer from the AS AK or AL size pumps See figure 10 Remove the seal seat or stationary part of seal from casing Disassemble thrust bearing assembly Remove outer snap ring from bearing housing for GG HJ or HL size pumps and ball bearing can be removed See figure 9 The AS AK and AL thrust bearing assembly has an li
10. ilt top of head back when removing to prevent this Avoid damaging head gasket Remove idler and bushing assembly If idler bushing needs replacing see Installation of Graphite Bushings page 7 Remove locknut from shaft See figure 9 or 10 A piece of brass or hardwood inserted in port opening and between rotor teeth will keep shaft from turning Loosen two setscrews in face of bearing housing and torn thrust bearing assembly counter clockwise and remove from casing See figure 9 or 10 Remove snap ring from shaft for GG HJ or HL size pumps see figure 9 Remove bearing spacer from shaft for AS AK amp AL size pumps see figure 10 10 Remove piece of brass or hardwood from port opening HEAD IDLER PIN SAFETY RELIEF VALVE gt CUTAWAY OF MODELS GG HJ or HL 4193 FIGURE 6 SECTION TSM 154 ISSUE B PAGE 3 OF 9 L Ly EXPLODED VIEW MODELS GG HJ and HL 493 and 4193 FIGURE 7 Ce sane cue o osmou i eroana e Raetvane C T fT Bemorosno meranese 16 eoma EXPLODED VIEW MODELS AS AK and AL 493 and 4193 FIGURE 8 NAME OF PART ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART Bearing Spacer Ae Relief Valve 18 Idler and Bushing Bearing Spacer Collar e Ball Bearing Inner 14 Pipe Plug as Head Gasket End Cap of Bearing Bearing Retainer Capscrew for Valve idler Pin Housing Washer r Seal tor Bearing Casing 4193 16 Rotor and Shaft ate Head and Idler Pin ousing 22 Capscr
11. mp was equipped with a relief valve and was removed during disassembly install on head with new gaskets Relief valve adjusting screw cap must always point towards suction port Refer to figure 5 page 2 For relief valve repair or adjustments see PRESSURE RELIEF VALVE INSTRUCTIONS page 7 Pack ball bearing with multi purpose grease NLGI 2 and install with casing with sealed side towards end of pump Install inner snap ring in GG HJ and HL size pumps See figure 9 NOTE AS AK and AL size pumps do not have a snap ring a bearing retainer washer must be assembled over end of shaft before the bearing is assembled See figure 10 Place bearing spacer over shaft and against single row ball bearing in casing AS AK and AL size pumps See figure 10 Install snap shaft ring in groove in the shaft GG HJ and HL size pump See figure 8 Pack lubrication chamber between inner ball bearing and double row ball bearing in the thrust bearing assembly approximately half full with multi purpose grease NLGI 2 See figures 9 and 10 Pack double row ball bearing with multi purpose grease NLGI 2 and press into bearing housing with shield side toward coupling end of shaft See Figure 9 AS AK and AL size pumps do not use a shielded bearing Install snap ring to hold bearing in place on GG HJ and HL size pumps NOTE On AS AK and AL size pumps install lip seal in bearing house end cap The lip should face towards end of shaft Put b
12. p cap and end seal that can be removed after loosening two set screws in flange of bearing housing Remove ball bearing See figure 10 3 Start seal seat in seal housing bore The casing should be examined for wear particularly in the area between ports All parts should be checked for wear before pump is put together When making major repairs such as replacing a rotor and shaft it is advisable to also in stall a new mechanical seal head and idler pin and bushing See Installation of Carbon Graphite Bushings page 7 Clean all parts thoroughly and examine for wear or damage Check lip seals ball bearings 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 non detergent SAE 30 weight oil and check for roughness Roughness can be determined by turning outer race by hand Replace bearings if bearings have roughness Be sure shaft is free from nicks burrs and foreign particles that might damage mechanical seal Scratches on shaft in seal area will provide leakage paths under mechanical seal ASSEMBLY Standard Mechanical Seal Synthetic Rubber Bellows Type The seal used in this pump simple to install and good performance will
13. re a record length of extension of adjusting screw 3 Refer to A on Figure 23 SECTION TSM 154 ISSUE B PAGE 7 OF 9 DISASSEMBLY DANGER BEFORE OPENING ANY VIKING PUMP LIQUID CHAMBER PUMPING CHAMBER RESERVOIR RELIEF VALVE ADJUSTING CAP FITTING ETC BE SURE 1 THAT ANY PRESSURE IN 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 Mark valve and head before disassembly to ensure proper reassembly 1 Remove valve cap 2 Measure a record length of extension of adjusting screw Refer to A on Figure 23 3 Loosen locknut and back out adjusting screw until spring pressure is being released 4 Remove bonnet spring guide spring and poppet from valve body Clean and inspect all parts for wear and damage and replace as necessary ASSEMBLY Reserve procedures outlined under Disassembly If valve is removed for repairs be sure to replace in same position Relief valve adj
14. result if care is taken during installation The principle of 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 Prior to installing rotating portion of mechanical seal prepare rotor shaft head and idler assemblies and appropriate gaskets for quick assembly Once rotating pressure of mechanical seal is installed on rotor shaft it is necessary to assemble parts as quickly as possible to ensure the 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 1 Coat idler pin with non detergent SAE 30 weight oil and place idler and bushing in idler pin on head If replacing a carbon graphite bushing refer to installation of Carbon Graphite Bushings page 7 2 Clean rotor hub and casing seal housing bore Make sure both are free from dirt and grit Coat outer diameter of seal seat and inner diameter of seal housing bore with non detergent SAE 30 weight oil If force is necessary protect seal face with a clean cardboard disc and gently tap it in place with a piece of wood SECTION TSM 154 ISSUE B PAGE 5 OF 9 SPRING MECHANICAL SEAL TAPERED SLEEVE COAT WITH LIGHT OIL BEFORE ASSEMBLY
15. s possible This will facilitate inspection adjustment and repair work and help prevent over looking a dirt covered grease fitting STORAGE If pump is to be stored or not used for six months or more pump must be drained and a 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 oil SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 4193 and 4936 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 set screw amp special mechanical seals 3 Snap ring pliers INTERNAL Viking P N 2 810 047 999 GG HJ HL 4193 493 EXTERNAL Viking P N 2 810 029 375 GG HJ HL 4193 493 4 Mechanical seal installation sleeve 2 751 001 900 for 3 4 inch seal GG HJ HL 4193 493 2 810 004 900 for 1 inch seal AS AL 4193 493 5 Bearing locknut spanner wrench Source 471 J H Williams amp Co or equal 6 Spanner wrench adjustable pin type for use on bearing housing end cap Source 482 J H Williams amp Co or equal 7 Brass bar 8 Arbor press SECTION TSM 154 ISSUE B PAGE 2 OF 9 DISASSEMBLY DANGER BEFORE OPENING ANY VIKING PUM
16. usting screw cap must a ways point towards suction valve of pump If pump rotation is reserved remove relief valve and turn end for end 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 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 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 pressure gauge in discharge line for actual adjustment operation 3 Turn adjusting screw 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 settings desired SECTION TSM 154 ISSUE B PAGE 8 OF 9 TECHNICAL SERVICE MANUAL VIKING SECTION TSM 154 PUMP HEAVY DUTY BRACKET MOUNTED PUMPS PAGE 9 OF 9 SERIES 4193 amp 493 ISSUE B SIZES GG AL VIKING PUMP WARRANTY Viking warrants all products manufactured by it to be
17. uthorized to alter this warranty IDEX CORPORATION IEX VIKING PUMP INC VIKING PUMP INC IDEX CORPORATION A Unit of IDEX Corporation Copyright 2000
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