TECHNICAL SERVICE MANUAL
Contents
1. Yellowish A press must be used for installation Figure 18 Measure the rotor to casing Lubricate the bushing and bore with soapy water Be certain bushing is started straight Do not stop pressing operation until bushing is in proper position Starting and stopping will result in a cracked bushing Check bushing for cracks after installation Soapy Water Not required Nitrallo Not required END CLEARANCE ADJUSTMENT The rotor and shaft assembly must be in the casing as far as possible Measure the distance between the rotor teeth and the outer face of the casing Figure 18 Measure the distance between the mounting surface and the first step on the head Figure 19 Subtract the two measurements and add your required end clearance Use 0 015 gaskets to attain the thickness as calculated above Place the gaskets on the head Figure 8 page 6 With the idler and bushing on the idler pin place the head and idler inside the rotor teeth Rotate into the proper position while pushing the head to the casing Bolt into place and tighten evenly PNEUMATIC TESTING Seal the ports with pipe plugs Be sure to provide a male air line connection to one of the ports Apply approximately 50 psi of air pressure to the pump Figure 20 Spray or brush the externals with soapy water and watch for growing air bubbles on any pump component These bubbles will indicate where leaks are occurring Relieve the pressure from2. VICAN PUMP CONTENTS Special Information 2 Maintenance 2 Packed Pump Breakdown Drawing 4 6 7 8 TECHNICAL SERVICE MANUAL secrion2 GENERAL PURPOSE JACKETED PUMPS BULLETIN TSM 230 C SERIES 230 ISSUE A MODELS HX4 KK LQ Q M N Packed Pump Disassembly Packed Pump Assembly Sealed Pump Breakdown Drawing Sealed Pump Disassembly 10 Sealed Pump Assembly 10 Installation of Carbon Graphite Bushings 11 End Clearance Adjustment 11 Pneumatic Test 11 Pressure Relief Valve Breakdown Drawing 12 Pressure Relief Valve Instructions 13 Pressure Adjustment 13 Troubleshooting 14 Inspection Form 15 Warranty 16 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 Vican representative Always give complete name of part part number and material with model number and serial number of pump when ordering repair parts The pump model number and serial number are on the nameplate In the Vican model number system basic size letters are combined with series number KK 230 with Jacketed casing head and rotor bearing sleeve UNMOUNTED PUMP UNITS HX4 230 KK 230 Units are designated by the unmounted pump model numbers followed by Arrangement LQ 230 Q 230 C svperpie _ x _ 0 Commercial Speed Reducer indicating drive style IBEX IDEX CORPORATION VICAN PUMP A Unit of Idex C
3. of the company products by the purchaser his employees or others The company will assume no field expense for service or parts unless authorized by it in advance Equipment and accessories purchased by the company from outside sources which are incorporated into any company product are warranted only to the extent of and by the original manufacturer s warranty or guarantee if any THIS IS THE COMPANY S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR INPLIED 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 the company is authorized to alter this warranty IDE CORPORA TIAN 2004 All Rights Reserved Vican Pump is a registered trademark of Viking Pump of Canada Inc IREX VICAN PUMP A Unit of Idex Corporation 661 Grove Ave Windsor Ontario N9A 6M3 Canada IDEX CORPORATION 16
4. seat retainer 9 Jacketed Casing Head gasket Casing and bushing assembly Idler pin 6 Setscrew____________ 13 fider_____________ 20 Head fasteners 7 Greasefiting 14 Jidlerbushing_____________ __________ MECHANICAL SEAL PUMPS Exploded View for Mechanical Seal Models LQ 230 Q 230 M 230 and N 230 Note KK 230 with jacketed RBS is bolt on as above but with 2 NPT jacketed casing NAME OF PART ITEM NAME OF PART eal seat retainer fasteners S Seal seat retainer R 6 SetScrews Head Gaskets 8 RotorBearingSleeve RBS 2 9 RBS amp Bushingassembly 21 _ RBS Gasket Jacketed Casing otor and Shaft assembly dler Bushing Idler and Bushing assembly en Mechanical Seal Cross Section Seal Seat Retainer Stationary Seat Casin Pipe Plu g e p g Driving Rin Rotating Seat jet ad DISSASSEMBLY OF SEALED PUMPS 1 Remove the fasteners from the seal seat retainer and pull it away from the seal chamber Remove the rotating seat and the spring from the shaft 2 Remove the pipe plug from the casing in the side of the seal chamber and loosen the 2 setscrews on the driving ring through the tapped hole in the side of the seal chamber Figure 16 3 Remove the driving ring from the shaft 4 Do steps 2 through 4 under DISASSEMBLY OF PACKED PUMPS 5 Do steps 6 through 10 under DISASSEMBLY OF PACKED PUMPS ASSEMBLY OF SEALED PUMPS The seal used in this pump is si
5. when assembling pump Remove idler and bushing assembly from the idler pin Tap the shaft forward with a softheaded hammer and pull it out of the casing and bushing assembly Large assemblies can be supported with a hoist and rope or strap around a rotor tooth The packing may be removed with a packing puller In some cases two pullers will be required or pushed out with a chisel and a hammer from the bushing side be careful not to damage the bushing If removal still cannot be done with the pullers or chisel stand the casing on the face of the stuffing box and press the bushing out through the packing area This will remove all of the packing with the bushing Clean all parts thoroughly and examine for wear and damage Check all parts for nicks burrs excessive wear and replace if necessary Check the bearings for roughness Roughness can be determined by turning the inner and outer race in opposite directions by hand Note if the motion is smooth and free or rough and stiff Smooth and free is desired The casing bushing can also be inspected while still in the casing If replacement is necessary and not already removed in step 5 stand the unit on the head mounting surface and push the bushing out with a round bar through the packing end of the casing Note For models Q M and N the rotor bearing sleeve can be removed from the casing to make 10 removal of the bushing easier If the idler pin is worn remove the grease fit
6. DATE PUMP MODEL SERIAL NUMBER CUSTOMER SALES ORDER NUMBER OTHER REFERENCE APPLICATION AND OR PROBLEM a ANY ROTOR O D O D wo e E Foo o ROTORTOOTHLENGTH ADLER OD ADLER BUSHING 1D IDLER TOOTH LENGTH ADLER PIN OD saarron O oo j o j o o SHAFTBUSHINGED J oo o o CRESCENTLENGTH Oooo S S o CASINGID O O j o j So o o END CLEARANCE ooo oo COMMENTS amp RECOMMENDATIONS VICAN PUMP TECHNICAL SERVICE MANUAL secriona GENERAL PURPOSE JACKETED PUMPS BULLETIN TSM 230 C SERIES 230 ISSUE A SIZES HX4 KK LQ Q M and N VICAN PUMP WARRANTY The company 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 the company If during said warranty period any products sold by the company prove to be defective in workmanship or material under normal use and service and if such products are returned to the company transportation charges prepaid and if the products are found by the company to be defective in workmanship or material they will be replaced or repaired free of charge F O B the company location The company 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
7. 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 Packing hooks flexible packed pumps Small for 1 4 inch and 3 8 inch cross section packing Large for 3 8 inch and larger cross section packing 4 Arbor press Strainers Use a strainer on the suction side of the pump to prevent foreign material from entering the pump causing damage to the gears and casing or lock up the pump Keep the strainer on the suction side of the pump clean and free of debris A blocked strainer will not allow sufficient liquid to reach the pump The lack of liquid reaching the pump will create cavitation Cavitation is when the liquid vaporizes on its way to the pump then returns to a liquid form on the surfaces of the pump This is very noisy damaging to a pump and seriously affects the output ie Figure 6 Casing bushing orientation Figure 7 Casing rotor amp shaft ass y PACKED PUMPS z a i I NE IO Y L E j Exploded View for Packed Models HX4 230 KK 230 with non jacketed rotor bearing sleeve ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART Packing Gland 7 Jacketed casing and bushing ass y Head Gasket Packing Gland fasteners 8 Pipe Plug Idler pin 3 Packing rings 9 RotorandShaftas
8. e rotor bearing sleeve which is mounted on the back side of the casing Figure 12 amp 13 4 Coat the shaft of the rotor and shaft assembly with non detergent SAE 30 weight oil Start the end of shaft in the casing bushing and slowly push the shaft through bushing Continue until the rotor and shaft assembly cannot move any further Figure 7 page 3 Perform all step in END CLEARANCE ADJUSTMENT page 11 Use only new packing suitable for the liquid being pumped Install the packing staggering the joints from one side of shaft to other Figure 9 page 6 If needed lubricate packing rings with oil grease or graphite to aid assembly Use the packing gland or a length of pipe to seat each packing ring Figure 10 page 6 Install packing gland capscrews and nuts Make sure the gland is installed square and nuts are only finger tight Figure 11 Refer to Packing Adjustment page 2 after the pump is assembled and installed Replace the grease fittings and pipe plugs Lubricate all grease fittings with multi purpose grease i A Y e Figure 11 Gland fasteners installed Figure 12 RBS bushing installation y Figure 13 Installing the Seal MECHANICAL SEAL PUMPS Exploded View for Mechanical Seal Models HX4 32 HX4 230 and KK 230 with non jacketed rotor bearing sleeve ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART Seal seat retainer fasteners 8 Casing bushing Idler and bushing assembly Seal
9. ecific lubrication questions PACKING ADJUSTMENT New packed pumps require initial packing adjustment to control leakage as packing runs in The adjustment should be made while the pump is operating with normal operating pressure on the discharge of the pump Make adjustments carefully and do not over tighten packing gland Evenly tighten the gland fasteners until the leak is reduced to a very slow drip If over tightened the packing will over heat score the shaft and reduce life After initial adjustment inspect periodically for increased leakage and re adjust Once the gland has been tightened to the stuffing box loosen the packing gland and add one ring to the stuffing box then adjust again Refer to instructions under Disassembly page 6 and Assembly page 7 regarding repacking pump CLEANING PUMP Keep pump as clean as possible This will facilitate inspection adjustment and repair work and help prevent overlooking a dirt covered grease fitting STORAGE lf pump is to be stored or not used for six months or more pump must be drained and a light coat of lubricant and rust preventative suitable to the application 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 the oil SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 32 pumps These tools are in
10. he seal seat spring and driving ring into the stuffing box so that the driving ring is visible through the access hole in the side of the seal chamber Rotate the shaft until the setscrews are accessible then tighten down the two setscrews on the ring Figure 16 8 Putthe seal seat retainer on the shaft with the stationary element facing toward the rotating element on the shaft 9 Start the fasteners on the retainer and tighten by hand until the seal faces touch and a small amount of pressure is applied by the spring Check that the retainer is centered and square with the shaft 10 Tighten the fasteners evenly and in small increments Figure 17 11 Replace the pipe plug in the hole in the side of the seal chamber Figure 17 Seal seat retainer installed 10 Replace the grease fittings and pipe plugs 11 Lubricate all grease fittings with multi purpose grease 10 INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing carbon graphite bushings extreme care must be taken to prevent breaking Carbon graphite is a brittle material and is 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 2 5 BUSHING MATERIALS Vican bushing material recommendations Material Appearance Installation Operating Lubricant Lubrication
11. ing No Discharge Pump priming may be required Suction lift is too great Relief valve is stuck open Strainer needs cleaning Wrong direction of rotation Air leeks in suction Speed is to slow Relief valve is set to low Suction lift too high for liquid handled This is very important on hot or volatile fluids Suction line is not submerged Suction piping too small in diameter or foot valve is to small Wrong rotation Pump internals worn Air or gases in suction piping Viscosity is higher than expected Relief valve set to low Air or gases in the fluid Pump internals are worn Insufficient volume being pumped Wrong rotation Improper clearances in the internals Suction line is leaking letting air into the pump Packing is too loose or the mechanical seal is leaking Leaking Gaskets Viscosity to high Discharge pressure is to high Insufficient lubrication Shaft or rotor bent misalignment or packing gland is to tight Noisy operation with good Misalignment of coupling Performance Worn bearings Noisy operation with poor or Cavitation Not enough fluid getting to the pump No performance Worn bearings or bushings Leaking around the shaft Packing is loose or needs replacement Mechanical seal is damaged or misaligned Shaft is scored Shaft is bent Insufficient Discharge Volume Insufficient Pressure Loss of suction after a period Of operation Excessive power requirement 14 PUMP INSPECTION REPORT
12. mple to install and good performance will result if care is taken during installation The principle of the mechanical seal is that contact between the rotary and stationary members These parts are lapped to a high finish and their sealing effectiveness depends on complete contact A number of pumps are supplied with special mechanical seals These special seals are not discussed in TSM 32 Information is available by contacting the factory When requesting special seal information be sure to give pump model number and serial number There is a wide variety of bushing materials available these materials should not all be treated the same See Bushing Material page 11 1 Repeat steps 1 through 5 of Packed Pump Assembly 2 Clean the oil off of the shaft and apply lubricant as recommended by your seal supplier to the shaft the inner diameter of the rotating element and the outer diameter of the stationary element of the mechanical seal 3 Place the o ring in the small groove in the seal seat 4 Press the stationary seat into the seal seat retainer while protecting the face as pictured in figure 14 5 Place the spring on driving ring with the setscrews already started in the threads Put the spring and ring on the shaft a PA ES Figure 16 Installing rotating seal 6 Slide the rotary member with the lapped contact surface facing away from spring onto shaft until components it is in the spring Figure 15 7 Push t
13. orporation 661 Grove Ave Windsor Ontario N9A 6M3 Canada DANGER BEFORE OPENING ANY 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 Rotary gear pumps operate equally well in a clockwise or counterclockwise rotation The shaft rotation determines which port is suction and which is discharge Port in area where pumping elements gear teeth come out of mesh is suction port PRESSURE RELIEF VALVES 1 Rotary gear pumps are positive displacement 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 those pump models designed to accept a relief valve Options may include a return
14. position Relief valve adjusting screw cap must always point towards suction side of pump If pump rotation is reversed remove relief valve and turn end for end Refer to Figures 2 3 page 2 PRESSURE ADJUSTMENT If a new spring is installed or if the 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 Install a pressure gauge in discharge line for actual adjustment operation Do this with all pressure relieved from the system 2 Carefully remove the bonnet which covers the adjusting screw 3 Loosen the lock nut which locks the adjusting screw so that the pressure setting will not change during operation of pump 4 With the pump operating read the pressure from the gauge There will be a leak around the adjusting screw 5 Turn adjusting screw in to increase pressure and out to decrease pressure Remember that the relief valve should not open during normal conditions 6 Closing a valve in the piping will stopping all flow A pressure gauge on the discharge port of the pump will show the maximum pressure that the relief valve will allow while pump is in operation IMPORTANT When 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 setting desired Figure 24 Bonne 13 Troubleshoot
15. sembly_______ 15 Head 6 Jacketedcasing 12 Jidlerand Bushing assembly_____ __ ______________ Exploded View for Packed Models LQ 230 Q 230 M 230 and N 230 Note KK 230 with jacketed rotor bearing sleeve is bolt on as above but with 2 NPT jacketed casing 1 Packing glandfasteners 8 Greasefitting 15 Headgasket 2 Packing Gland________ 9 RBSGasket________ 16 Jldlerpin____________ 6 RBSandbushingass y 13 ldlerbushing____________ 20 Headfasteners_____ Packed Cross Section l Casing Zed SSS Packing Gland Packing Rings Casing Bushing DISASSEMBLY OF PACKED PUMPS Note For large pump models the use of a lifting device is advised 1 Remove the packing gland fastener and pull the gland out of the stuffing box and off of the shaft Mark head and casing before disassembly to insure proper re assembly The idler pin which is offset in pump head must be positioned toward and centered between the port connections to allow for proper flow of liquid through pump Figure 1 page 2 Remove head from pump Do not allow idler to fall from idler pin Tilt top of head back and down when removing to prevent this The idler and bushing should stay on the idler pin If pump is furnished with pressure relief valve it need not be removed from head or disassembled at this point Refer to Pressure Relief Valve Instructions page 12 The gaskets must be totally removed Use new gasket
16. the pump Carefully disconnect the air supply Remove the plugs or covers from the ports Return the pump to service 11 PRESSURE RELIEF VALVE INSTRUCTIONS A Size VDOOOO Q oO lt UGAZ Wy Sees SS lt A a ure a TTS pons a 2 JAdjustingScrew___ 5 Endcap 8 Spring 11 Relief valve port gasket 3 Bonneto ring 6 SpringGuide 9 Poppe DISASSEMBLY Mark valve and head before disassembly to insure proper reassembly 1 Remove bonnet 2 Measure and record length of adjusting screw protruding out of the end cap 3 Loosen locknut and back out adjusting screw until spring pressure is released 4 Remove relief valve cap spring guide spring and poppet from valve body Clean and inspect all parts for wear or damage and replace as necessary ASSEMBLY 1 Clean and inspect all parts for wear or damage and replace as necessary Insert the poppet spring and spring guide into the valve body Figures 21 22 2 Put two gaskets on the cap and install it into the relief valve body Figure 21 Poppet 3 Put the adjusting screw into the relief valve cap so that the portion protruding out of the end cap is the same as that measured from disassembly Figure 23 4 Lock the adjusting screw into location with the lock nut 5 Put the o ring over the threads on the relief valve cap and install the bonnet Figure 24 If valve is removed for repairs be sure to replace in same
17. ting and support the casing on the crescent side as close as possible to the idler pin Press the pin out If the idler bushing is worn it can be pressed out of the idler However the idler will likely be worn as mush as the bushing therefore it is recommended that the complete assembly be replaced Figure 9 Alternate the packing cuts s i tee rt Rep a z ka all T et ce ell A E She eee 10 Pushing in the packing ee A Figure rings ASSEMBLY OF PACKED PUMPS Rotary gear pumps are supplied with a wide variety of bushing materials These materials should not all be treated the same See Bushing Material page 11 a Press the idler bushing into the idler gear Figure 4 page 3 Refer to Installation of Carbon Graphite Bushing see page 11 Note Some bushings have a small step in the diameter on one end to assist in the alignment and starting 2 Coat the idler pin with non detergent SAE 30 weight oil and using the idler bushing as a guide press the idler pin into the head with the tapped hole in and the groove pointing toward the center of the crescent Figure 5 page 3 Install the casing bushing If the bushing has a lubrication groove install bushing with the lubrication hole aligned with the grease fitting hole on the casing Figure 6 page 3 If carbon graphite refer to Installation of Carbon Graphite Bushings page 11 Note Q M N and R pumps have RBS bushings installed in th
18. to tank relief valve and a jacketed relief valve Pumps equipped with a jacketed head are not available with a relief valve 3 If pump rotation is reversed during operation pressure protection must be provided on both sides of pump 4 Relief valve bonnet must a ways point towards suction side of pump If pump rotation is reversed remove pressure relief valve and turn end for end Figures 2 and 3 show the 2 possible configurations Figure 2 has side suction and top discharge Figure 3 has top suction and side discharge The shaft turns in the opposite direction on the second pump 5 Pressure relief valves cannot be used to control pump flow or regulate discharge pressure SPECIAL INFORMATION SPECIAL MECHANICAL SEALS can be installed either next to rotor hub or behind the bracket bushing Extra care must be taken in repair of pumps with mechanical seals Read and follow all special information supplied with pump MAINTENANCE Series 32 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 life ee E Figure LUBRICATION External lubrication must be applied slowly with a handgun to all lubrication fittings every 500 hours of operation with multi purpose grease Do not over grease Applications involving very high or low temperatures will require other types of lubrication Consult factory with sp
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