TECHNICAL SERVICE MANUAL
Contents
1. IDLER BUSHING IDLER PIN 8 Loosen two axial setscrews in bearing housing flange 7 Da and remove the bearing housing from bracket DISCHARGE J SUCTION SIDE OF PUMP v4 pice ge OFPUMP 9 Examine the closures in the bearing housing and end PUMP HEAD Tg cap These closures are important to this assembly and p ia should be replaced if not in first class condition CHECK VALVE _ CHECK VALVE OPEN ANS AN CLOSED When installing new closures be sure they are NaS US assembled with the lip facing toward the locknut N See Figure 11 SASS 10 The casing should be examined for wear particularly at the seal area between port openings If this surface FIGURE 3 is in good condition the casing in all probability may be used However should a defective check valve be removed from the i suction side of the head it must be replaced with a new check 11 If KK 260 G See Figure 5 remove the needle bearing waive from the bracket If 200 G Series see Step 12 2 Remove the idler and bushing assembly from the idler Remove the stationary seal seat being careful not to pin Replace all excessively worn parts If it is necessary damage the lapped surface of the seat See Figure 7 to install a new carbon graphite bushing extreme care Using snap ring pliers remove the snap ring located at should be taken to prevent breaking when it is being the end of the needle bearing The bearing is now free installed in the idler If2. shaft as far as it will go Replace keepers Install the bearing housing and closure in the bracket Pack the ball bearing with grease place on the shaft and push or drive into place in the housing Turn the bearing end cap with closure and bearing collar inside into the bearing housing until tight against the bearing Lock in place by the setscrews in the outside diameter of the bearing housing Put lockwasher and locknut on shaft Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Tighten locknut to 100 130 ft Ibs Torque K KK L LQ LL If tang does not line up with slot tighten locknut until it does Failure to tighten locknut or engage lockwasher tang could result in early bearing failure and cause damage to pump Remove length of hardwood or brass from port opening 10 Adjust the pump end clearance HEAD ROTOR FIGURE 11 THRUST BEARING ADJUSTMENTS See Figure 11 1 NOTE Be sure the shaft can rotate freely Loosen the two set screws A in the outer face of the bearing housing B and turn this thrust bearing assembly B clockwise until it can no longer be turned by hand Back off counterclockwise only until the rotor shaft can be turned by hand with a slight noticeable drag For standard end clearance back off the thrust bearing assembly B the required number of notches or an equivalent length measured on the outside o
3. ESB 515 Consult factory with specific lubrication questions 2 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 assembly of the pump for information regarding this procedure 3 CLEANING THE PUMP It is good practice to keep the pump as clean as possible This will facilitate inspection adjustment and repair work and help prevent omission of lubrication to fittings covered or hidden with dirt 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 200 and 260 pumps These tools are in addition to standard mechanics tools such as open end wrenches pliers screwdrivers etc Most of the items can be obtained from an industrial supply house 1 Soft Headed Hammer 2 Allen Wrenches some mechanical seals and set collars 3 Mechanical seal installation sleeve Bearing locknut spanner wrench Source Grainger 1APC4 5 Spanner wrench adjustable pin type for use on double end caps Source Grainger 1APC1 Brass Bar Arbor Press DISASSEMBLY DANGER Before disassembling a pump or removing it from t
4. Electronic copies of the most current TSM issue can be found on the Viking Pump website at www vikingpump com TECHNICAL SERVICE MANUAL VIKING BRACKET MOUNTED LP GAS PUMPS SERIES 200 G AND 260 G E j E z Th kn B F CONTENTS Introduction aoa a 2 ee 1 Safety Information 206 4 2 Special Information 3 Maintenance 2 0 00 2 ee eee 3 Disassembly 0 000 eee eee 5 Assembly 2 02 ee ee ee ee es 6 Thrust Bearing Adjustment 6 Pressure Relief Valve Instructions 6 Warranty 4a an we 6 eo oe oe ee we we ee oD 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 Units are designated by the unmounted pump model numbers followed by a letter s indicating drive style V V Belt D Direct Drive R Viking Speed Reducer P Commercial Speed Reducer This manual deals exclusively with the 200 G and 260 G series bracket mounted LP Gas pumps Refer to figures 1 13 for general configuratio
5. UMP 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 ae Warning In addition to possible serious Symbol Paner E FAETO ONON Me naea eg injury or death failure to follow the instruction may result in serious injury DORNING indicated instruction may cause damage Legend g or death to pump and or other equipment BEFORE opening any liquid chamber pumping WARNING INSTALL pressure gauges sensors next to the chamber reservoir relief valve adjusting cap fitting pump suction and discharge connections to monitor etc be sure that pressures e Any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections USE extreme caution when lifting the pump Suitable lifting devices should be used when appropriate Lifting e The pump drive system means motor turbine eyes installed on the pump must be used only to lift engine etc has been locked out or otherwise WARNING the pump not the pump with drive and or base plate been made non operational so that it cannot be If the pump is moun
6. a sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precautionary measures may result in serious injury or death 1 Remove the head from the pump Avoid damaging the O ring head gasket If the pump has a relief valve on the head the valve may be removed but this is not necessary SECTION TSM 443 ISSUE C PAGE 4 OF 8 CAUTION WHEN THE HEAD IS BEING REMOVED FROM THE PUMP THE IDLER USUALLY STAYS ON THE IDLER PIN BUT WILL FALL OFF IF THE INSIDE OF THE HEAD IS TILTED DOWNWARD Always keep your feet in the clear should this part fall A fall on a hard surface can damage the idler If the idler should fall check carefully and file or stone all nicked or rough places before re assembly Using a pencil inspect the check valves located at the base of the idler pin in the head See Figure 3 The ball on the inside of these fittings should be depressed with the point of the pencil to insure that the valve is not stuck If the spring behind the ball does not hold the ball in a closed position or if the spring is broken remove the check valve from the head If a defective check valve is removed from the discharge side of the head it need not be replaced and can be discarded CAUTION IF THE CHECK VALVE IS LEFT OUT OF THE DISCHARGE SIDE OF THE HEAD THE PUMP MUST NEVER BE RUN IN THE OPPOSITE DIRECTION WITHOUT INSTALLING A NEW CHECK VALVE
7. f startup provided that in no event shall this warranty extend 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 vikingopump com IMPORTANT In ordering parts for relief valve on head always be sure to give Model and Serial Number of pump as it appears on nameplate and the name of the part wanted When ordering springs be sure to give the pressure setting desired If valve is removed for repairs be sure to replace in same position The return to tank valve
8. f the bearing housing See the following table TURN BRG HOUSING C C W NO OF NOTCHES OR LENGTH ON O INCHES 4 1 Tighten the two self locking type Allen set screws A in the outboard face of the bearing housing with equal force against the bracket Your pump is now set with standard end clearances and locked If not back off additional notches and check again 4 For specific recommendations consult the factory Each additional notch or each 0 25 on the outside diameter of the bearing housing is equivalent to an extra end clearance of 0015 on K KK L LQ and LL size pumps VALVE INSTRUCTIONS AZN 6 Gin ieee BA fi 000 00O O Ezz hg SSO r FIGURE 12 VALVE LIST OF PARTS Valve Cap Valve Body Adjusting Screw Lock Nut Valve Spring Poppet Cap Gasket Bonnet Gasket Spring Guide Bonnet SECTION TSM 443 ISSUE C PAGE 7 OF 8 TECHNICAL SERVICE MANUAL MOUNTED LP GAS PUMPS SERIES 200 G AND 260 G DISASSEMBLY DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on
9. he 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 SECTION TSM 443 ISSUE C PAGE 3 OF 8 Grease Fitting Closure Bearing Housing Bearing Spacer Collar Mechanical Seal O Ring Gasket Back Flange Bearing Housing with Setscrews EA E E E Pipe Plug 18 19 20 Rotor and Shaft 21 22 Idler Idler Bushing Ti d 63 s TEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART Pressure Relief Plug 23 O Ring Gasket Head 24 Idler Pin 25 Check Valve Bracket Bushing Needle Bearing and Snap Ring on KK 250G Only 26 Head Valve Type and Idler Pin ae Peery 29 orny 20 Caper or vane and Cover Pate Tat Feum To Tan Reevahe Toa ove FIGURE 2 Exploded View Series 200G amp 260G Pumps 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 dat
10. ing pumps are positive placement pumps and must be provided with some sort of pressure protection Series 200 G and 260 G pumps are only available with a return to tank relief valve 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 either turn end for end or change position with the cover plate 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 1 LUBRICATION Periodic external lubrication should be applied slowly with a handgun at all lubrication fittings provided A good quality of general purpose grease is satisfactory in the majority of cases however applications involving low temperatures may require other types of lubricants Suggested frequency of lubrication is once every 500 hours of operation with multi purpose grease NLGI 2 Do not over grease Applications involving low temperatures will require other types of lubrication Refer to Engineering Service Bulleting
11. it is cracked in the idler this to be removed bushing will quickly disintegrate An arbor press should The bearing should be washed thoroughly and be used to install carbon graphite bushings Be sure examined If there is any evidence of wear or damage bushing is started straight DO NOT STOP the pressing a new bearing should be used operation until the bushing is in the proper position Also examine the bearing surface on the shaft This Starting and stopping this operation invariably results in f is bitted tis st de d that a bushing failure surface is pitted or worn it is strongly recommended tha l a new rotor shaft and needle bearing be installed 2 Bena eek ae ieee apace ee 12 If series 200 G the bracket bushing should be inspected ee ee ee eee ues He and if it shows signs of wear should be replaced This pple a None OF ie estes peveet MG TOLON carbon graphite bushing must be removed from the teeth and into the casing port will prevent the rotor from casing end of the pump If it is necessary to install a raring new carbon graphite bracket bushing the same care 4 Drive the shaft forward approximately 0 50 inch and should be taken as in Step 2 when replacing the carbon inspect for the presence of a pair of half circle round graphite idler bushing WE KEE PET oe unaer He heating ee deel Cola 13 Mechanical Seal If the mechanical seal in your pump If present these rings must be removed before the rotor fails it b i laced with i and
12. line pressure relief valve temperature or change the system duty parameters WARNING a torque limiting device or a rupture disk If pump from those the pump was originally supplied without rotation may be reversed during operation pressure WARNING confirming its suitability for the new service protection must be provided on both sides of pump Relief valve adjusting screw caps must always point towards suction side of the pump If pump rotation is reversed position of the relief valve must be changed Pressure relief valves cannot be used to control pump Pp PP BEFORE operating the pump be sure that e Itis clean and free from debris Pip PPP WARNING all valves in the suction and discharge pipelines flow or regulate discharge pressure For additional are fully opened information refer to Viking Pump s Technical Service e All piping connected to the pump is fully supported ngs TSM 000 and Engineering Service Bulletin and correctly aligned with the pump e Pump rotation is correct for the desired direction of flow 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 WARNING pump operation SECTION TSM 443 ISSUE C PAGE 2 OF 8 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 Vik
13. n and nomenclature used in this manual CAUTION THE 200 G AND 260 G SERIES ARE UL LISTED PUMPS ANY CHANGES OR REPAIRS TO THE PUMP WILL VOID 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 CORPORATION SECTION TSM 443 PAGE 1 OF 8 ISSUE C SIZES K KK L LQ LL FIGURE 1 200 G 260 G SERIES UNMOUNTED PUMP 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 VIKING PUMP INC A Unit of IDEX Corporation Cedar Falls IA 50613 USA SAFETY INFORMATION AND INSTRUCTIONS IMPROPER INSTALLATION OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY OR DEATH AND OR RESULT IN DAMAGE TO P
14. nce of wear or damage a new bearing should be used FIGURE 4 CUTAWAY VIEW 200 G SERIES SECTION TSM 443 ISSUE C PAGE 5 OF 8 LIPSEAL FOR SEAL CHAMBER SECTION TSM 443 ISSUE C BRACKET SEAL HOUSING SEAL SEAT GASKET SEAL SEAT SPRING ROTARY MEMBER FIGURE 5 CUTAWAY VIEW 260 G SERIES ASSEMBLY 1 Installing New Seal The seal is simple to install and good performance will result if care is taken in its installation NOTE Never touch the sealing faces with anything except the fingers or a clean cloth Clean the rotor hub and bracket seal housing making sure both are free from dirt and grit Coat the outside 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 as shown in Figures 6 amp 7 COAT WITH LIGHT OIL SS BEFORE ASSEMBLY W 3 Y AX D Z Grs FIGURE 6 200 G SERIES COAT WITH LIGHT OIL BEFORE ASSEMBLY FIGURE 7 260 G SERIES PAGE 6 OF 8 SPRING MECHANICAL SEAL ROTARY MEMBER _ hi it TAPERED SLEEVE COAT WITH LIGHT OIL BEFORE ASSEMBLY FIGURE 8 Place the tapered sleeve furnished with replacement seals on the shaft as in Figure 8 Coat the inside of the rotary member and the outside of the tapered sleeve with light oil Place the spring and rotary member on the shaft over the sleeve and against the hub of the rotor only enough t
15. o hold the spring in position Do not compress spring at this stage See Figure 9 Remove the tapered sleeve FIGURE 9 Refill the bracket lubrication chamber with multi purpose grease and place the tapered sleeve in the bracket closure as shown in Figure 10 Flush the sealing faces of both the rotary member and stationary member with oil just before installing rotor and shaft LIPSEAL FOR SEAL CHAMBER Yh LILLLLLLLLLLLLE N se A ih I 3 Install the rotor and shaft Place the end of the shaft in the bracket bushing or needle bearing Turn from right to left slowly pushing it into place until the end of the rotor teeth are just below the face of the casing Placing the head and idler on the casing will force the rotor to its proper depth Be sure the shaft is free from burrs and foreign particles that might damage the bracket bushing or needle bearing Remove the tapered sleeve from the shaft Place the O ring head gasket on the head NOTE BE SURE THE O RING LOCATION ON THE HEAD IS FREE OF DIRT AND SCALE BEFORE INSTALLING THE O RING 4 Place the head on the pump With the idler on the idler pin put the head on the pump and tighten the capscrews Tilt the top of the head away from the pump slightly until the crescent enters the inside diameter of the rotor and rotate the idler until its teeth mesh with the rotor teeth This will help in putting the head on the pump Place the bearing collar on the
16. 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 DANGER BE SURE VALVE AND SYSTEM ARE FREE OF LP GAS 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 s and poppet from the valve body Clean and inspect all parts for wear or damage and replace as necessary ASSEMBLY Follow the procedure outlined under Disassembly Remember to replace gaskets and re set and lock adjusting screw CORPORATION VIKING PUMP INC A Unit of IDEX Corporation Cedar Falls IA 50613 USA SECTION TSM 443 PAGE 8 OF 8 ISSUE C SIZES K KK L LQ LL VIKING PUMP CORPORATION 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 o
17. shaft can be removed from the pump Carefully ee ee ee ee ee ee ee l There are three basic parts to this seal They are the remove the rotor and shaft from the pump i spring the rotary member and the stationary seal seat The spring and rotating member of the mechanical seal See Figures 4 or 5 Remove the spring and rotary will come out with the shaft member from the shaft and the stationary seal seat from the bracket The principle of the mechanical seal is the contact between the rotary and stationary members CAUTION These parts are lapped to a high finish and their sealing UNLESS THE SEAL IS DEFECTIVE DO effectiveness depends upon complete contact NOT REMOVE THE ROTARY MEMBER FROM THE SHAFT REMOVAL OF THE SEAL WILL LIKELY CAUSE LEAKAGE BRACKET SEAL HOUSING WHEN REINSTALLED SEAL SEAT GASKET SEAL SEAT E 5 Inspect the bracket closure and replace it if not in first Fi LIPSEAL FOR SEAL CHAMBER class condition If this closure is replaced be sure the new closure is installed with the lip facing IN toward the mechanical seal Recent models have double lip closure facing both ways A i om 6 Loosen the radial socket head set screws in outer ring of bearing housing and remove the bearing housing end cap closure and bearing spacer collar Use a spanner wrench to remove the end cap SPRING ROTARY MEMBER 7 Remove the double row ball bearing The bearing should be washed thoroughly and examined If there is any evide
18. should be on the discharge side of the pump All rights reserved 3 2013 Viking Pump Inc
19. ted on a base plate the base plate started while work is being done on the pump 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 i gt e 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 DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is BEFORE operating the pump be sure all drive guards mounted on a pump that is operating are in place 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 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 i THE PUMP must be provided with pressure protection This may be provided through a relief valve mounted DO NOT exceed the pump s rated pressure speed directly on the pump an in
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