Service Instruction No
Contents
1. oy X9 L 3109 sdund 5 5 F 250 ssulysng TERIEN PAS F 200 asec IBI oje dooe q ui sSungsn 107 s e9S IO pepuejg F 150 uels D pepuejs p1epuejs g 10j 5 p1epuejs sjeliajey dung p epuejg LL LL LL o o o LO 50 100 F Viton and Teflon oil seals can be used in place of standard oil seals upon request Teflon and Gore Tex gaskets can be used in place of standard seals upon request 5 9 06 Page 6 of 28 v 1 4 WARNING 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 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 If the fluid is incompatible then the pump must be fully flushed prior to use If the pump is to be operated at elevated temperatur2. 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 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 If the 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 Pumps can run dry provided provisions are made for the mechanical seal if one is used Failure to comply with this could cause severe damage to the mechanical seal parts Pump needs to be earthed separately to avoid a buildup of electro static charge v1 4 Page 3 of 28 5 9 06 General Description The design of the Tuthill Industrial Series incorporates externally timed impellers which are supported in the fluid
3. 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 1 4 Page 10 of 28 5 9 06 v1 4 Page 11 of 28 5 9 06 General Parts List For 5A 10 16 25A 65 and 125A Pumps Description Thrust Bearing Description Cap Screw Timing Gears Dowel Pin Square Key Packing Gear Key Packing Gland Cl Drive Shaft Cl SS SS V Ring Driven Shaft Cl Stud SS Washer Impeller Key Cl Nut SS Gear Case Bushing Impellers Cl S L Lip Seal SS S L Pipe Plug Locknut Gear Case Faceplate Bushing Gear Case Cover Bushing SS Pumps Only Gear Case Cover Wing Nut Expansion Plug Stud Vented Pipe Plug Faceplate Cl Nametag SS Drive Screw Gasket Cap Screw Impeller Housing Cl Pipe Plug Cl SS SS Housing Bushings Cl Bronze Bushing 005 SS Carbon Bushing Exact quantities will vary depending upon actual pump model are Cast Iron pumps that will have corresponding steel and or ductile iron components SS are Stainless Steel pumps that will have corresponding stainless steel components Recommended spare parts are i
4. 5A 10 16 amp 25A Page 22 Disassembly of Relief Valve 65 125A amp 125H Page 22 Assembly of Relief Valve 65 125A amp 125H Page 23 24 Packing Section Page 25 Serial Number Location Page 26 Common Pump Problems Page 27 Troubleshooting Page 28 Material Returns Warranty Contact Information 1 4 Page 2 of 28 5 9 06 Introduction The HD 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 HD 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 HD 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 typically 12 13 digits but can be 18 digits serial number name of part part number if known and part material Service Manual 72 for the HD Series pumps is available at www tuthillpump com The materials furnished for each pump are selected to suit individual applications WARNING WARNING
5. and pumping temperature See Page 14 Hot clearances are for pumps rated for applications in excess of 150 F 66 C Hot clearance impellers have an H stamped on hub face closest to impeller housing Standard clearance impellers are not stamped 15 Replace impeller and nut on driven shaft and torque nut as required 16 Remove shaft nut and impeller from drive shaft 17 Repeat Step 13 for driven shaft 18 Replace impeller and nut on drive shaft and torque nut as required 19 Recheck clearance and timing 20 Apply grease to gear case face and press gasket in place 21 Assemble gear case cover and tighten screws Rotate drive shaft to assure smooth operation 22 Assemble housing gasket and faceplate and tighten nuts Rotate drive shaft to assure smooth operation 23 Install drain pipe plug 24 Remove oil level plug and fill plug Fill with oil to level hole See Lubrication Schedule on Pg 9 25 Install oil level plug and fill plug Note Use vented plug 32 for the fill hole 26 Repack stuffing box See Page 23 for proper installation of packing rings 27 Snug up packing gland nuts 28 Pump is now ready for service Adjust packing leakage gradually for 2 to 3 drops a minute WARNING WARNING Coupling hubs or sheaves must be slip fit on drive shaft Shock loads from a hammer or mallet can upset impeller clearances resulting in immediate pump failure Major Disassembly Instructions Models 65 and 125A Refer
6. wheel 2 full threads Set valve for bypass pressure To do this first install a pressure gage in the discharge line Turn hand wheel clockwise until pressure stops increasing More turns will cause the relief valve to operate at higher pressure The valve is now seated and the pump is discharging at full capacity Page 22 of 28 5 9 06 Packing for HD Standard Duty Pumps Installing Packing in Pumps 1 Remove all old packing using a packing hook Clean stuffing box and shaft thoroughly and examine shaft for wear or scoring Check bearings for wear as this can cause an eccentric shaft rotation resulting in excessive leakage Packings will not act as a bearing If shaft surface is worn replace shaft or have seal surface area resurfaced 2 Becertain the proper size packing is used The following packing sizes will apply Pump Model Packing Size Shaft Diameter No of Rings 5A 10 amp 16 1 4 Square 3 4 4 25A 1 4 Square 1 4 65 1 4 Square 1 3 8 4 125A 1 4 Square 1 3 8 6 3 Always cut packings into separate rings Never coil around shaft standard factory packings are pre cut and pre formed If bulk packing is used cut each ring on a mandrel the same size as the pump shaft Try rings in stuffing box to be certain that each ring fills the seal chamber and that there is no gap between packing joints 4 Install one ring at a time seating each ring independently Use clean oil to lubricate shaft and inside of stu
7. 1 Remove faceplate 13 If faceplate does not pull off easily it may require a slight tap with a mallet Remove lock nuts 9 from ends of shafts To facilitate this operation you can wedge a small block of wood or other soft material between the impellers Loosen both nuts in this manner before removing Slide impellers from shafts Mark impellers so they can be replaced on the same shaft Remove all burrs on drive shaft with a mill file or emery paper Also remove any deposits of paint Special care should be taken around the keyway and shaft end This is where burrs are most likely to be found Drain the oil from the gear case by removing lower drainpipe plug Remove six cap screws 17 from gear case cover 30 Remove gear case cover by sliding over drive shaft Loosen packing gland nuts 24 and slide packing glands out of stuffing boxes Note Pumps with mechanical seals require special handling and these instructions are shipped with the pump Examine gears for factory timing marks prior to removal Timing marks should be visible at gear tooth base and consist of two punch marks on the drive shaft gear and one punch mark on the mating tooth cavity on the driven shaft gear In the event these marks are not provided gears should be marked at this time Timing gears are press fitted on the shafts and this feature maintains pump clearance setting Use a gear puller to remove timing gears Remove gear keys Pull drive 5 and driven s
8. 28 5 9 06 12 13 14 15 16 17 18 19 Remove burrs on the shaft that may have occurred during gear removal Loosen packing gland nuts and slide packing glands out of stuffing boxes Note Pumps with mechanical seals require special handling and these instructions are shipped with the pump Pull shafts out of pump from faceplate side V rings 21 will also need to be removed from the opposite end of the shafts at this time All parts should be inspected for wear and damage Replace worn or damaged parts Bushings in the housing gear case and gear case cover are removed by being pressed out Faceplate bushings if supplied are either carbon or glass filled Teflon To remove excessively worn Teflon bushings carefully slit them and remove To remove excessively worn carbon bushings carefully break them and remove the pieces Lip seals 26 in gear case will be pressed out at the same time as the bushings Lip seal and expansion plug 31 in gear case cover will be pressed out at the same time as the bushings Major Reassembly Instructions Models 65 and 125A Refer to Parts Diagram on Page 11 1 gt 12 13 14 1 4 Press new bushings into housing gear case and gear case cover Press oil seals into place Refer to Page 16 for proper installation When replacing gear case bushings make sure oil holes line up with cast grooves in the hubs Replace expansion plug Faceplate
9. INSTALLATION AND SERVICE INSTRUCTIONS HD SERIES PUMPS STANDARD uii MODELS TUTH LL 12500 South Pulaski Road Alsip Illinois USA 60803 Pu mp Group Tel 389 2500 Eon 708 0869 ail tuthillpumpe tuthill c xn thill com v1 4 Page 1 of 28 5 9 06 WARNING WARNING Read Manual before operating or working on a Tuthill HD pump Table Of Contents Page 3 Introduction Page 4 General Description Pumping Principle HD Models Page 5 HD Model Numbering System Page 6 Temperature Limits Page 7 Installation Page 8 Packing Adjustments Page 9 Lubrication Requirements Recommended Lubricants Page 10 Inspection and Repair Page 11 Parts Diagram Page 12 General Parts List 5A 10 16 25A 65 amp 125A Pumps Page 13 Minor Disassembly Instructions 5A 10 16 25A 65 amp 125A Pumps Page 13 Minor Assembly Instructions 5A 10 16 25A 65 amp 125A Pumps Page 14 Pump Clearances 5A 10 16 25A 65 amp 125A Pumps Page 15 Major Disassembly Instructions 5A 10 16 amp 25A Pumps Page 16 17 Major Assembly Instructions 5A 10 16 amp 25A Pumps Page 17 18 Major Disassembly Instructions 65 amp 125A Page 18 19 Major Assembly Instructions 65 amp 125A Page 20 Disassembly of 3 1 Gear Reduction Unit 10 amp 16 Page 20 Assembly of 3 1 Gear Reduction Unit 5A 10 amp 16 Page 21 Disassembly of Relief Valve 5 10 16 amp 25A Page 22 Reassembly of Relief Valve
10. Page 15 Reassembly of 3 1 Gear Reduction Unit for Models 5A 10 amp 16 The following instructions pertain only to the Models 5A 10 and 16 pumps with optional 3 1 gear reduction unit Refer to Page 21 for part identification hp OG Go Assemble entire pump except for the gear reduction unit per Pages 16 17 Steps 1 17 If timing is correct place short spacer 4 reduction gear 6 a long spacer 7 and cone bearing 8 on upper gear reduction shaft Also place spacer 5 and cone bearing 8 on bottom shaft Apply grease to housing gasket seal surface Press gasket in place Slide gear reduction cover over shafts revolving pinion shaft to mesh with gear reduction gears Tighten six screws holding cover in place Remove oil level plug and fill plug Fill with oil to level hole See lubrication recommendations on Page 9 v 1 4 Page 20 of 28 5 9 06 item Part Description Qty Part Numbers Impeller Key 2 P500 19 S4 P500 19 S4 P500 19 S4 Gear Reduction Shaft 10619300 10619300 10619400 Gear Key 10511700 10511700 10511700 Short Upper Spacer 10618700 10618700 10618700 Lower Shaft Spacer 10618800 10618800 10618800 Reduction Gear 10618600 10618600 10618600 Long Upper Spacer 10636500 Cone Bearing P652 9 P652 9 P652 9 Gear Reduction Cover 10618300 10618300 10618300 Hex Cap Screw P101 6 H P101 6 H P101 6 H Pinion Shaft Assembly 10673700 10673700 10673700 Pinion Shaft Seal P941 14 P941 14 P941 14 Bearing Cu
11. Pump leaks a Bolts need tightening allowing gaskets or O rings to leak b Gaskets or O rings are damaged Note Packings are designed to leak Leakage should be at a rate that will prevent excessive heating on the bracket at the packing area 1 4 Page 27 of 28 5 9 06 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 has been 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 to pump failure Because of the unpredictable nature of fluids encountered pumps are not warranted for any specific life Contact Information If additional information is required to facilitate ope
12. They cause the greatest damage to equipment and present difficulties for packing In general this involves flush purges and temperature control Hard facing on the shaft seal surfaces such as stellite or ceramic are also recommended When pumping slurries and abrasives an external source of clear or otherwise suitable liquid must be force fed at a pressure higher than that existing in the stuffing box This differential pressure is in the area of 10 25 psi Suspended Solids Solids which are suspended in liquids and which are an inherent part of their structure would include starch clay slurry muddy water and other similar slurries This is best handled by an external 1 4 Page 23 of 28 5 9 06 flush of clear liquid through a lantern ring as shown This arrangement will result in a small amount of product dilution and is controlled by the differential pressure in the seal chamber Inlet AZZAN XE SS Clean Licuid LASER AN Packing with Internal Flush How To Pack For Congealing Liquids These liquids congeal either because of a change in temperature or as a result in drying out after exposure to air Clay coatings and latex fall into both categories A good rule is to keep the fluid moving before congealing can take place Control with cooling or heat and or by flush or purge Some products harden to a solid state when exposed to air Clay coatings latex and sugars are examples An effective f
13. Use a soft faced vise to hold shaft and impeller while the shaft nuts are torqued per Page 13 Slide the shaft gear assemblies through the housing but not yet into the gear case Install the V rings 21 on the shafts V rings should be staggered such that the bottom ring is closer to the gear case This is easily adjusted after pump is completely assembled by sliding the rings on the shaft 8 Continue sliding shaft gear assemblies through the gear case until the impeller contacts the housing 9 Assemble timing gear keys 4 10 Slide timing gears 2 over shafts until they are partially engaged with the keys 11 Set the timing per the picture shown below Gears that have been in service and marked may be used as timing will be correct X and Y dimensions should be equal when meshing gears to set timing The normal identification method for timing is two punch marks on the drive shaft gear tooth and one mark on the driven shaft gear mating cavity Rotate shaft one full revolution to assure correct timing wh 1 4 Page 16 of 28 5 9 06 12 Press both timing gears onto shafts 13 Remove shaft nut and impeller from driven shaft See Page 15 Steps 3 and 4 for proper procedure 14 Press or tap gear case end of drive shaft 5 to required setting clearance Clearance is checked with a feeler gage between impeller lobe face and impeller housing bottom face This clearance will vary with material of construction
14. be operated in either direction The direction of flow is dependent on the direction of rotation of the pump drive shaft When facing the drive shaft of the pump a clockwise rotation provides a left hand suction port and a right hand discharge port Flow would be from the left to right when facing the drive shaft Packing Adjustment WARNING 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 All packings must leak to perform properly Their purpose is to control leakage not to prevent it The slight leakage along the shaft provides proper lubrication to the packing Pump packings have a lubricant that acts as a primary sealant for the start up and break in phases during which this lubricant acts to reduce friction Once the pump is on the line external lubrication must be supplied to the packing to keep it running properly and to attain longer life If external lubrication is not supplied the lubrication in the packings will bleed out due to heat generation Heat is a primary cause of packing failure Pumps with packing will require periodic adjustment To accomplish this gently and evenly tighten the 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 acce
15. bushings if supplied are pressed in until bottomed Replace packing glands and thread packing gland nuts loosely on studs Assemble impeller keys impellers and shaft nuts on the shafts Use a soft faced vise to hold shaft and impeller while the shaft nuts are torqued per Page 13 Slide the shaft gear assemblies through the housing but not yet into the gear case Install the V rings on the shafts V rings should be staggered such that the bottom ring is closer to the gear case This is easily adjusted after pump is completely assembled by sliding the rings on the shaft Continue sliding shaft gear assemblies through the gear case until the impeller contacts the housing Assemble timing gear keys Slide timing gears over shafts until they are partially engaged with the keys Set the timing per picture below Gears that have been in service and marked may be used as timing will be correct and Y dimensions should be equal when meshing gears to set timing The normal identification method for timing is two punch marks on the drive shaft gear tooth and one mark on the driven shaft gear mating cavity Rotate shaft one full revolution to assure correct timing Press both timing gears onto shafts Remove shaft nut and impeller from driven shaft See Page 17 Steps 3 and 4 for proper procedure Press or tap gear case end of drive shaft to required setting clearance Clearance is checked with a feeler gage between impeller lobe
16. ce must be exercised for best pump service life Ambient conditions temperature humidity dust etc can alter schedule Gear Case First Oil Subsequent Model No Capacity CC Change Hrs Change Hrs 5A 10 amp 16 150 500 3000 25A 150 500 3000 65 amp 125A 1650 500 3000 Above standard lubricants are adequate for operating temperatures between 100 F and 350 F If temperature exceeds 350 F use the following Oil Specification Lubriplate APG 250 or equal Bearing Grease 930 AA or equal 1 4 Page 9 of 28 5 9 06 Inspection and 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 See following pages for exploded pump view and instructions WARNING 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
17. chamber by double row ball bearings located out of the product stream This design enables the Industrial Series to handle highly viscous abrasive slurries corrosive acids or suspended solids without degradation aeration or contamination of the product PUMPING PRINCIPLE Here s how it works Rotating impellers develop a vacuum at inlet drawing material into the cavity positive action of the impellers displaces material forcing discharge at pump outlet Ports are always open sealing action between impellers and housing prevents fluid flow return HD Models Material of s Max Capacity Port Size Construction Speed USGPM LPM PSI BAR External NPT Ductile Iron Same As Above Same As Above Stainless Same As Above Same As Above Same As Above Same As Above v1 4 Page 4 of 28 5 9 06 HD PROCESS PUMP NUMBERING SYSTEM oe O2 STANDARD DUTY O4 STANDARD DUTY DIGITS 1 amp 2 O1 INDUSTRIAL DUTY ID SD SD Ductile Iron Only Stainless Steel Only 03 Madel 34 01 Model 5A 14 Model 2A 02 Model 10 16 Model 70A 03 Model 16 DIGITS 3 amp 4 29 Model 3A 05 Model 25A 31 Model 120A 14 Model 65 75 Model 330 26 Model 125A 91 Model 600 04 316 Stainless Steel O1 amp O4 Models DIGITS S 6 09 Ductile Iron O1 amp O2 Models DIGIT 7 0 Internal NPT Std on ID mode
18. es 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 Pumps can run dry provided provisions are made for the mechanical seal if one is used Failure to comply with this could cause severe damage to the mechanical seal parts Pump needs to be earthed separately to avoid a buildup 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 Pumps should be filled with liquid at installation 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 othe
19. face and impeller housing bottom face This clearance will vary with material of construction and pumping temperature See Page 14 Hot clearances are for pumps rated for applications in excess of 150 F 66 C Hot clearance impellers have an Page 18 of 28 5 9 06 stamped on hub face closest to impeller housing Standard clearance impellers are not stamped 15 Replace impeller and nut on driven shaft and torque nut as required 16 Remove shaft nut and impeller from drive shaft 17 Repeat Step 13 for driven shaft 18 Replace impeller and nut on drive shaft and torque nut as required 19 Recheck clearance and timing 20 Apply grease to gear case face and press gasket in place 21 Install thrust bearing and shims into timing gear counter bore 22 If necessary add or remove shims to provide 0 0005 0 0010 0 013 0 025 mm axial shaft play 23 Assemble gear case cover and tighten screws Rotate drive shaft to assure smooth operation 24 Assemble housing gasket and faceplate and tighten nuts Rotate drive shaft to assure smooth operation 25 Install drain pipe plug 26 Remove oil level plug and fill plug Fill with oil to level hole See Lubrication Schedule on Pg 9 27 Install oil level plug and fill plug Note Use vented plug 32 for the fill hole 28 Repack stuffing box See Page 23 for proper installation of packing rings 29 Snug up packing gland nuts 30 Pump is now ready for service Adjust packin
20. ffing box Joints should be staggered and kept at least 90 apart Each individual ring should be firmly seated with a tamping tool Never depend entirely on the gland to seat a set of packings This practice will jam the last rings installed but leave the front rings loose The result is excessive and rapid wear 5 After last ring is installed tighten gland nuts finger tight Then start pump and take up nuts until leakage is decreased Stopping leakage at this point will cause packing to burn If temperature rises in seal area back off on packing nuts as this indicates excessive gland pressure 6 Allow packing to leak freely for at least one hour when starting up a newly packed pump Take up gland nuts gradually 1 16 turn every 5 10 minutes until leakage stabilizes at about 2 3 drops per minute If temperature in seal area increases back off and start over Note Replace packing when leakage cannot be controlled by further take up of gland Test results indicate that 70 of the wear occurs on the first two rings of packing nearest the gland Rings next to the gland work the hardest The rings in the bottom of the stuffing box serve to throttle some fluid pressure On abrasive service the bottom ring takes most of the beating Therefore this ring should be a firm ring How to Pack for Abrasive Liquids As used here Abrasives is a broad term intended to cover the problem of packing against slurries congealing liquids and the likes
21. g leakage gradually for 2 3 drops a minute WARNING WARNING Coupling hubs or sheaves must be slip fit on drive shaft Shock loads from a hammer or mallet can upset impeller clearances resulting in immediate pump failure 1 4 Page 19 of 28 5 9 06 Disassembly of 3 1 Gear Reduction Unit for Models 5A 10 amp 16 The following instructions pertain only to the Models 5A 10 and 16 pumps with optional 3 1 gear reduction unit Refer to Page 21 for part identification 1 6 Drain oil from gear case by removing lower drain plug Remove size screws 10 on face of gear reduction cover Remove cover 9 by sliding over shafts Remove cone bearing 8 long spacer 7 reduction gear 6 short spacer 5 and timing gear from top gear reduction shaft Also remove cone bearing spacer and timing gear from lower gear reduction shaft Note Check timing gears for timing marks per Page 17 Step 9 If timing gears are not marked mark them before removing To replace pinion shaft assembly 1 press assembly out of hub Oil seal 12 will remain on shaft Press new shaft assembly in place Slip oil seal over shaft and press into oil seal bore To replace cup bearing first remove adjusting plug 14 with spanner wrench Insert new bearing cup and screw adjusting plug partially in Adjust plugs after reassembly of gear reduction unit All play should be removed from cone bearing To disassemble entire pump see instructions on
22. h dial indicator Rotating elements Disassemble and y v binding inspect Disassemble pipe v pipe pump and re align before 9 reassembling 2 Check setting and Relief valve chattering valve seating Excessive system Check for obstructions in P discharge line Sung perdas 199 Repack and adjust Check pump Pump speed low impeller speed Have pump Pump parts worn reconditioned or replace worn parts nmm Check discharge oe piping and valves 9 for obstruction v Wrong direction of Reverse motor rotation Suction line sized too Increase suction 4 v small piping size Torque control coupling not adjusted Readjust coupling v1 4 Page 26 of 28 5 9 06 Troubleshooting 1 Problem No fluid is delivered a Poweris not on b Net positive suction head available NPSHa is lower than required for the vapor pressure of the liquid pumped You should calculate NPSHa and redesign piping if necessary c There are leaks in suction line d Direction of shaft rotation is incorrect e Relief valve setting is too low if the pump is equipped with a relief valve Liquid is discharging through the by pass port Problem Capacity is too low a There are air leaks in suction line b Suction 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
23. haft 6 out through the faceplate side V rings 21 will also need to be removed from the opposite end of the shafts at this time All parts should be inspected for wear and damage Replace worn or damaged parts Faceplate bushings 10 if supplied are either carbon or glass filled Teflon To remove excessively worn Teflon bushings carefully slit them and remove To remove excessively worn carbon bushings carefully break them and remove the pieces Lip seals 26 in gear case will be pressed out at the same time as the bushings Lip seal and expansion plug 31 in gear case cover will be pressed out at the same time as the bushings Page 15 of 28 5 9 06 Major Reassembly Instructions Models 5A 10 16 and 25 Refer to Parts Diagram on Page 11 1 Press new bushings into housing gear case and gear case cover Press lip seals into place Refer to diagram for proper installation When replacing gear case bushings make sure oil holes line up with cast grooves in the hubs TSS d az llt HOUSI NG IS XC FACEPLATE Pump Model X Housing X Gear Case 10 amp 16 5 32 4 mm 5 32 4 mm 25A 5 32 4 mm 0 65 amp 125 3 8 10 mm 0 Replace expansion plug 31 Faceplate bushings 10 if supplied are pressed in until bottomed Replace packing glands 20 and thread packing gland nuts loosely on studs Assemble impeller keys 7 impellers 8 and shaft nuts 9 on the shafts
24. ls 1 External NPT Standard on SD models DIGIT 8 0 No Relief Valve 1 Relief Valve Available on all SD models amp ID models 30 2A 3A 70A 120A 01 Hot Clearance 02 Special Shaft Material 05 Special Packing 06 Special Packing Configuration 08 Mechanical Seals 09 Special Bushings DIGITS 9 amp 10 10 Special Clearances 13 Steam Jacket Tracing 19 Special Ports Flanged etc 21 Tutriding 26 Interference Fit Gears 27 Special U Cup Lip Seals 28 Miscellaneous DIGITS 11 amp 12 01 02 Etc Serialized at the factory DIGIT 13 D Double Lobe Available ID models only If Required T Teflon housing and faceplate bushings SD Models 1 4 Page 5 of 28 5 9 06 TEMPERATURE LIMITS OF HD PROCESS PUMP MATERIALS 600 F 550 F sdumq ING peasy ssulysng uoq 1e aseg 1822 Sc 43H asec je dooe q 107 s e9g IO asec pue oje dooe q 10 s e9S UOMA sdumgq S S Sjoxsex Sse 2 uopo L SsuIYysng uoq re F 500 F 450 F 400 sduin F 350 d Surqoeq p repuejg sdumg ssurysng ozuoagq s1o oduuq o2ute9 SSe F 300 jonq asec asec
25. lush is shown Note that this type of flush does not enter the product but only mixes with the product leakage This arrangement also tends to serve as a cooling medium for the seal chamber Packing with External Flush 1 4 Page 24 of 28 5 9 06 Serial Number Location The Serial Number Nameplate is located as shown in the Parts Diagram on Page 11 Item 33 In addition to the nameplate the serial number is also stamped on top of the impeller housing 15 This serial number should be furnished to Tuthill whenever service parts are required and when questions regarding pump design or construction arise 1 4 Page 25 of 28 5 9 06 Common Causes of Pump Problems Symptoms o gt Sr gt gi E 9 9 E E F Possible Cause Suggested Solution 8r z 8 sg z Ss Sa L 9 S g 2 9 gt Suction life high for Reduce vacuum v 4 v vapor pressure of liquid requirements Liquid too viscous for Reduce pump v v 4 Air leakage in suction Tighten and seal all 4 v piping joints Suction pipe not Lengthen suction v liquid pipe q supply tank Suction strainer Clean strainer or a clogged or of use larger size insufficient area Misalignment between align dae coupling alignment Pump wit
26. n bold text When ordering spare parts please specify pump model serial number part number amp part name 1 4 Page 12 of 28 5 9 06 Disassembly amp Reassembly Instructions for 5A 10 16 25A 65 and 125A Pumps Minor Disassembly For Fluid Chamber Inspection Refer to Parts Diagram on Page 11 1 2 Remove six faceplate wing nuts 11 Remove faceplate 13 If faceplate does not pull off easily it may require a slight tap with a mallet Remove lock nuts 9 from ends of shafts To facilitate this operation you can wedge a small block of wood or other soft material between the impellers Loosen both nuts in this manner before removing Slide impellers 8 from shafts Mark impellers so they can be replaced on the same shaft The fluid chamber is now ready for inspection Reassemble In Accordance With Minor Reassembly Instructions Refer to Parts Diagram on Page 11 1 2 oou v 1 4 Replace impeller 8 and impeller keys 7 on appropriate shafts Install lock nuts on end of shafts Use piece of wood or other soft material wedged between the impellers as described above The torque required to lock the shaft nuts is listed below Standard Models Torque ft Ibs 5A 10 16 25A 40 45 65 125A 50 55 Check clearances between lobe face and housing bottom face dimension B on page 14 If clearances are incorrect reset clearances according to reassembly instructions on the following pages Model
27. p P652 10 P652 10 P652 10 Adjusting Plug 10606300 10606300 10606300 Key 12313700 12313700 12313700 00 NI gt O1 BR Oo Po Po a Po Disassembly of Relief Valve for Models 5A 10 16 amp 25A All Standard Duty pumps are available with optional pressure relief valves The valve when supplied is built into the faceplate Therefore servicing of the valve is a minor disassembly procedure which can be performed without disturbing the pump mounting piping or installation Note The adjustment end of the valve must be on the suction side of the pump for proper operation Remove locknut and O ring Remove sanitary nut Plug and valve housing subassembly may then be removed and separated Remove spring and valve PONS Part Number 1 Locknut Stainless Steel 10596800 10597500 Locknut O Ring Viton std P701 22 77 P701 26 77 Sanitary Nut Nickel Alloy P208 1 S P208 2 S Threaded Plug Stainless Steel 10596700 10597400 Valve Housing Stainless Steel 10596500 10597200 Spring Stainless Steel 10597000 10597700 Valve Stainless Steel 10596400 10597100 Cast Iron 13900901 13903401 Stainless Steel 42002601 42004700 10541800 10543300 Faceplate NMI Faceplate Bushing Teflon v1 4 Page 21 of 28 5 9 06 Includes bushings Reassembly of Relief Valve fo
28. ptable If excessive leakage persists after complete adjustment consider re packing the stuffing box or using another packing type v1 4 Page 8 of 28 5 9 06 Lubrication Requirements Housing Bushing Housing bushings are fully lubricated by the pumped fluid and are maintenance free Gear Case Bearings Bearings are splashed lubricated Bearings are designed to provide a minimum L10 life of 15 000 hours at maximum speed and pressure conditions and are splashed lubricated Lubrication Instructions For Tuthill Process Pumps The oil used in the gear case of the process pumps is Lubriplate APG9 Lubriplate is a trade name of Fiske Brothers Refining Company Toledo Ohio Cil specifications are as follows Viscosity at 100 F 816 SSU Viscosity at 212 F 86 SSU API Gravity 26 5 Flash Point 39 F Fire Point 440 F Extreme Pressure Additives Any 90 weight gear oil may be substituted if equivalent to above The grease used in the faceplate ball bearing of the Industrial Series pump is Lubriplate 1200 2 Grease specifications are as follows Lithium Base N L G I 2 Work Penetration 280 A S T M Dropping Point 450 F Minimum Oil Viscosity at 100 F 950SSU Water resistant with rust and corrosion inhibitors added Any 2 bearing grease may be substituted if equivalent to above The following charts on lubrication requirements are offered as a guide only Common sense approach to preventative maintenan
29. r Models 5A 10 16 amp 25A 9o 7 Check beveled end of valve for burrs or damage If present correct before assembly Install valve on seat in faceplate Place spring on valve stem Engage threaded plug approximately 3 4 of the length of the valve housing Place plug and valve subassembly over valve stem Tighten sanitary nut to capture valve assembly Set valve for bypass pressure To do this first install a pressure gauge in the discharge line Turn valve housing clockwise until pressure stops increasing More turns will cause the relief valve to operate at higher pressure The valve is now seated and pump is discharging at full capacity Install O ring and locknut Disassembly of Relief Valve for Models 65 125A amp 125H 1 2 Remove adjustment nut or hand wheel Remove spring valve and O ring subassembly Part Number Hand Wheel Stainless Steel Spring Stainless Steel Valve Stainless Steel Buna std Viton opt Cast Iron Stainless Steel Bushing Carbon Includes bushings 10592700 20386800 20339600 P701 36 37 P701 36 77 13904109 50314600 50309600 O ring Faceplate ed a Reassembly of Relief Valve for Models 65 125A amp 125H ON gt v 1 4 Check beveled end of valve for burrs or damage If present correct before assembly Place O ring and valve assembly in valve seat Place spring over stem Engage hand
30. r 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 If a 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 v1 4 Page 7 of 28 5 9 06 Pumps are positive displacement pumps and must be used in conjunction with a pressure relief mechanism 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 expect the 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 Direction of Flow Tuthill Industrial Process Pumps may
31. ration or maintenance contact the authorized Tuthill distributor shown below Information on Tuthill contacts can also be obtained at www tuthillpump com European Contact Info Tuthill Pump Group Manners Industrial Estate Ilkeston Derbyshire DE7 8YA England tuthilluk tuthill com North America Contact Info Tuthill Pump Group 12500 South Pulaski Road Alsip Illinois 60803 U S A www tuthillpump com v 14 Page 28 of 28 5 9 06
32. s 5A 10 16 25A or Section 6 65 125A Rotate driveshaft several revolutions to assure proper timing Clean housing gasket face of any burrs Place new gasket 14 on impeller housing If original gasket is in good condition it can be reused Replace faceplate 13 and six faceplate wing nuts 11 Rotate assembled pump driveshaft several revolutions to be certain that there is no interference or rubbing If no interference is apparent the pump is ready to be put back in service Page 13 of 28 5 9 06 Chamber Clearances Faceplate gaskets are compressed to approximately 003 004 inches when pump bolts are tightened For impeller assembly settings and resultant clearances see below A B MODEL IMPELLER RESULTING SIDE C D MATERIAL SETTING CLEARANCE onran RESULTING CLEARANCES SIDE OPPOSITE SIDE PASS OVER IN MAX MIN MAX MIN MAX MIN MAX Models 5A amp 10 Hot Hot Model 16 Hot Hot Model 25A Hot Hot Models 65 125A amp 125H Hot Hot SINGLE LOBE IMPELLER Check to ensure that pump still rotates freely FACEPLATE MATING IMPELLER v1 4 Page 14 of 28 5 9 06 Major Disassembly Instructions Models 5A 10 16 and 25 Refer to Parts Diagram on Page 11 1 2 10 11 12 13 Bushings in the housing gear case and gear case cover are removed by being pressed out 15 16 17 v 1 4 Remove six faceplate wing nuts 1
33. to Parts Diagram on Page 11 1 Remove six faceplate wing nuts 11 Remove faceplate 13 If faceplate does not pull off easily it may require a slight tap with a mallet 3 Remove lock nuts 9 from ends of shafts To facilitate this operation you can wedge a small block of wood or other soft material between the impellers Loosen both nuts in this manner before removing 4 Slide impellers from shafts Mark impellers so they can be replaced on the same shaft 5 Remove all burrs on drive shaft with a mill file or emery paper Also remove any deposits of paint Special care should be taken around the keyway and shaft end This is where burrs are most likely to be found 6 Drain the oil from the gear case by removing lower drainpipe plug 7 Remove six cap screws 17 from gear case cover Remove gear case cover by sliding over drive shaft 8 Remove thrust bearings 1 and shims 37 and identify them so they can be correctly reassembled later 9 Examine gears for factory timing marks prior to removal Timing marks should be visible at gear tooth base and consist of two punch marks on the drive shaft gear and one punch mark on the mating tooth cavity on the driven shaft gear In the event these marks are not provided gears should be marked at this time 10 Timing gears are press fitted on the shafts and this feature maintains pump clearance setting Use a gear puller to remove timing gears 11 Remove gear keys 1 4 Page 17 of
34. vacuum gauge directly at the pump suction The maximum vacuum at the pump suction should never exceed 15 of mercury Vaporization caused by higher vacuums will generally result in capacity drop off Redesign suction conditions Pump speed is too slow Strainer is too small or obstructed Suction pipe or port is not immersed in liquid deep enough Piping is improperly installed permitting an air pocket to form in the pump Increased clearances or wear in the pump will sometimes cause the pump to deliver an insufficient supply of liquid Problem Pump works spasmodically a Leaky suction lines b Suction conditions vary Air or vapor is in the liquid Problem Excessive power draw Pressure is too high Liquid is more viscous than originally expected Suction or discharge line is obstructed There is insufficient horsepower There are mechanical defects i Drive shaft and pump are misaligned ii Pump is binding due to incorrect clearance setting iii Pump shaft is bent iv There is misalignment within pump due to bad piping or poor installation causing strain or distortion Problem Pump is noisy Pump is cavitating due to inadequate suction conditions There is misalignment of coupling Coupling is set too close to pump There is vibration of the pump due to a worn or bent shaft There are air leaks on suction side of pump or air entrainment in the fluid Problem
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