TECHNICAL SERVICE MANUAL
Contents
1. the pump Pump rotation is correct for the desired direction of flow ISSUE C PAGE 2 OF 8 to pump and or other equipment INSTALL pressure gauges sensors next to the pump suction and discharge connections to monitor pressures USE extreme caution when lifting the pump Suitable lifting devices should be used when appropriate Lifting eyes installed on the pump must be used only to lift the pump not the pump with drive and or base plate If the pump is mounted on a base plate the base plate 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 DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is mounted on a pump that is operating 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 THE PUMP must be provided with pressure protection This may be provided through a relief valve mounted directly on the pump an in line pressure relief valve a torque limiting device or a rupture disk If pump rotation may be reversed during operation pressure protection must be provided on both side2. E 8 OF 8 ISSUE Cc VIKING PUMP IBEX 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 of 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 IN
3. ELIEF VALVE PRESSURE ADJUSTMENT If a new spring is installed or if the pressure setting of the pressure relief valve is changed from what the factory has set the following instructions must be carefully followed 1 Carefully remove the valve cap that covers the adjusting 77 screw Note this cap will most likely contain liquid Mi jj 2 Loosen the locknut that keeps the adjusting screw from W A turning while the pump is in operation 3 Install a pressure gauge in the discharge line This will be required for the pressure adjustment operation 4 Turn the adjusting screw in to increase the pressure and out to decrease the pressure 5 With the discharge line closed at a point beyond the pressure gauge the gauge will show the maximum FIGURE 9 pressure that the valve will allow while the pump is in SIZES ATE amp ALE operation VALVE LIST OF PARTS IMPORTANT Valve Cap Valve Body When ordering parts for a pressure relief valve always Adjusting Screw Valve Spring give the model number and serial number of the pump as Lock Nut Poppet it appears on the nameplate Also specify the name of the part s wanted When ordering springs be sure to give the pressure settings desired Spring Guide Cap Gasket Bonnet Bonnet Gasket SECTION TSM 710 1 ISSUE C PAGE 7 OF 8 TECHNICAL SERVICE MANUAL INDUSTRIAL HEAVY DUTY MOTOR SPEED PUMPS SERIES 4076 AND 4176 SIZES HLE ATE AND ALE SECTION TSM 710 1 PAG
4. Electronic copies of the most current TSM issue can be found on the Viking Pump website at www vikingpump com TECHNICAL SERVICE MANUAL tcron tsu 7104 INDUSTRIAL HEAVY DUTY MOTOR SPEED PUMPS pace 10F8 SERIES 4076 AND 4176 SIZES HLE ATE AND ALE ISSUE Cc CONTENTS Introduction 2 22204 4 1 Safety Information 04 2 Special Information 04 3 Rotation 2 02020000 3 Pressure Relief Valves 3 Maintenance 2 2045 3 Lubrication 2 2004 3 Cleaning the Pump 3 Storage a ee ee oe a Bo a ee we o E 3 Suggested Repair Tools 3 Disassembly 2 0 2 soa ccana aoa aor ee b ia 4 Assembly e csr k tega i y on e o a T et 4 Mechanical Seal aoaaa aaa a 5 Thrust Bearing Adjustment 5 FIGURE 1 Installation of Carbon Graphite Bushings 6 Model HLE4176 Installation of Foot 2 2 2 6 Shown with relief valve on pump casing and foot mounting Pressure Relief Valve Instructions 6 Relief Valve Pressure Adjustment 6 INTRODUCTION The illustrations used in this manual are for identification purposes only and cannot be used for ordering parts Obtain a parts list from the factory or a Viking representative Always give complete name of part part number and material with model number and serial number of pump when ordering repair parts The pump model n
5. FRINGEMENT ALL OF WHICH OTHER WARRANTIES ARE EXPRESSLY EXCLUDED See complete warranty at www vikingpump com 3 2013 Viking Pump Inc All rights reserved CORPORATION VIKING PUMP INC A Unit of IDEX Corporation Cedar Falls IA 50613 USA
6. Pato Ontona 10 O Ring ForSealSeat 22 Casingbusting f aa Sheoc OOOO OOOO E 1 mechanical Sea 28 Cover Piate Pumps Less Valve Z Reqd on ATE BALE Not mus Pipe Flange Gasket Redg 12 Grease Fitng 24 CapscrensorRelefvaieorCoverPate TABLE 2 8 Install the lip seal in the end cap See FIGURE 4 for lip 11 Insert a length of hardwood or brass through either port orientation Thread the end cap into the bearing housing opening between the rotor teeth This will keep the shaft along with the outer bearing spacer collar Tighten the from turning when the lock nut is tightened Install the end cap Lock the end cap in place with two radial lock nut and tighten to 70 95 Nem on HLE pumps and setscrews in the flange of the bearing housing 135 175 Nem on ATE and ALE pumps 9 See FIGURE 7 and notes under MECHANICAL 12 Adjust the pump end clearance as described in SEAL on this page Lubricate the outside diameter of THRUST BEARING ADJUSTMENT on page 6 the seat gasket and install the stationary member of the 43 Lubricate the grease fitting with multi purpose grease mechanical seal into the end of the bearing housing NLGI 2 Note the shinny side of the seal seat faces out 10 Slide the inner bearing spacer collar onto the shaft Thread the bearing housing assembly into the bracket SECTION TSM 710 1 ISSUE C PAGE 5 OF 8 DANGER Before starting the pump be sure all drive equipment guards are in place F
7. Y 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 1 Remove the head capscrews Remove the head of the pump Do not allow the idler to fall from the idler pin To prevent this from happening tilt the top of the head back when removing Avoid damaging the head o ring f the pump is furnished with a jacketed head plate it will separate from the head when the capscrews are removed Avoid damaging the jacketed head plate o ring Remove the idler and bushing assembly Insert a length of hardwood or brass through either port opening between the rotor teeth to keep the shaft from turning Remove the lock nut using a standard open end wrench 4 Loosen the two setscrews in the face of the bearing housing and unthread the beari
8. ailure to properly mount guards may result in serious injury or death MECHANICAL SEAL For disassembly see DISASSEMBLY on page 4 For assembly see ASSEMBLY on page 4 NOTE Never touch the mechanical seal faces with anything except clean hands or a clean cloth Minute particles can scratch the seal faces and cause leakage Always clean the rotor and shaft and seal housing bore before installing the mechanical seal Make sure surfaces are clean and free of scratches There are two available mechanical seals The standard features a cup type seat A pin style seal is also available that has the seal seat pinned to prevent rotation This design is used for viscosities higher than 750 cPs BEAR ING HOUS ING oN SEAT GASKET ROTAT ING STATIONARY FACE MEMBER ROTATING FACE FIGURE 7 THRUST BEARING ADJUSTMENT See FIGURE 4 on page 3 1 Loosen the two setscrews in the outer face of the bearing housing and turn the thrust bearing assembly clockwise until it can no longer be turned by hand Back off counterclockwise until the rotor shaft can be turned by hand with a slight noticeable drag 2 For standard end clearance back off the thrust bearing assembly the required length as measured on the outside diameter of the bearing housing See Table 3 3 Tighten the two self locking type Allen setscrews in the outboard face of the bearing hou
9. e equipped with a removable foot Removal of the foot is not normally required for maintenance In cases where the foot needs to be replaced or is being added use the following steps 1 Ensure alignment pins are installed in the top of the foot prior to assembly of the foot to the casing 2 Match the foot to the casing by inserting pins into the bottom of the casing 3 Secure foot to casing using the socket head capscrews and lock washers Torque capscrews to 100 110 Nem PRESSURE RELIEF VALVE INSTRUCTIONS 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 FIGURE 8 engine etc has been locked out or SIZE HLE made non operational so that it cannot be started while work is being done on pump VALVE LIST OF PARTS Valve Cap Valve Body 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 Adjusting Screw Valve Spring Lock Nut Poppet Bonnet Cap Gasket Spring Guide Failure to follow above listed precautionary measures may result in serious injury or death R
10. ication fitting every 500 hours of operation with multi purpose grease NLGI 2 Do not over grease Applications involving very high or low temperatures will require other types of lubrication Refer to Engineering Service Bulletin ESB 515 Consult factory with specific lubrication questions Note that the bushings used in this pump do not require any external lubrication CLEANING THE PUMP Keep the pump as clean as possible This will facilitate inspection adjustment and repair work and help prevent overlooking a dirt covered grease fitting STORAGE If the pump is to be stored or not used for six months or more pump must be drained and a light coat of non detergent SAE 30 weight oil must be applied to all internal pump parts Lubricate the fittings and apply grease to the pump shaft extension Viking suggests rotating the 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 Viking series 4076 4176 pumps These tools are in addition to standard mechanics tools such as open end wrenches pliers and screw drivers Most items can be obtained from an industrial supply house 1 Soft headed hammer 2 Allen wrenches 3 Bearing locknut spanner wrench 4 Spanner wrench adjustable pin type for use on bearing housing end cap Brass bar or wood block Arbor press on SECTION TSM 710 1 ISSUE C PAGE 3 OF 8 DISASSEMBL
11. ng housing assembly from the bracket The end of the bearing housing contains the mechanical seal seat Avoid damaging this surface See FIGURE 4 5 Remove the rotor and shaft assembly being careful to avoid damaging the mechanical seal face and casing bushing 6 Remove the rotating member of the mechanical seal from the shaft only if the seal is to be replaced ASSEMBLY NOTE To facilitate assembly place the pump casing so that it is standing on one of its flanges with a block of wood under the mounting flange See FIGURE 5 SECTION TSM 710 1 ISSUE C PAGE 4 OF 8 BALL BEARING BEARING HOUSING SETSCREW NYLON INSERT SPACER COLLAR SHAFT STATIONARY MECHAN ICAL SEAL_ SEAT LOCATION LIPSEAL END CAP LIPSEAL SETSCREW FIGURE 4 FIGURE 5 1 Install the casing bushing See INSTALLATION OF CARBON GRAPHITE BUSHINGS on page 6 2 Apply alight coating of oil onto the shaft in the seal area install the rotating member of the mechanical seal onto the rotor and shaft assembly Slide the seal all the way to the shoulder on the shaft 3 Slide the rotor and shaft assembly into the casing taking care not to damage the bushing or the mechanical seal face NOTE When installing a new rotor and shaft assembly use a file to carefully remove all burrs and sharp edges 4 Coat the head o ring with oil or grease and slip it over the head pilot to keep it in place Apply a coating of light oil onto the bu
12. oove in the head Standard rotation is clockwise as viewed from the shaft end If rotation is to be reversed the following items need to be changed 1 The head and pin assembly must be replaced 2 Position of the relief valve will have to be changed Install so the adjusting screw cap points towards the suction side of the pump 3 The flush line must be switched to the opposite port LOADING GROOVE FIGURE 3 Counter Clockwise Rotation Shown PRESSURE RELIEF VALVES Viking pumps are positive displacement pumps and must be provided with some form of pressure protection This may be a relief valve mounted directly on the pump an in line pressure relief valve a torque limiting device or a rupture disk Pumps equipped with relief valves have them mounted on the casing If pump rotation is reversed during operation pressure protection must be provided on both the sides of the pump The relief valve adjusting screw cap must always point towards the pump suction port Pressure relief valves are intended for use as a protection for the pump only and should not be used to control pump flow or regulate discharge pressure MAINTENANCE Viking 4076 4176 pumps are designed for long trouble free service life under a variety of application conditions with a minimum of maintenance The following points will help provide long service life LUBRICATION External lubrication must be applied slowly with a hand gun to the lubr
13. s 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 flow or regulate discharge pressure For additional information refer to Viking Pump s Technical Service Manual TSM 000 and Engineering Service Bulletin ESB 31 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 pump operation 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 the 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 the above listed precautionary measures may result in serious injury or death ROTATION See Figure 3 Viking 4076 4176 pumps are directional due to the loading gr
14. shing inside diameter and the crescent Place the idler and bushing assembly onto the idler pin NOTE When installing a new head and pin assembly use a file to carefully remove all burrs and sharp edges especially around the loading groove 5 Install the head For proper head positioning the pin should be at the top centered between the two ports If the pump is equipped with a jacketed head plate make sure the o ring is in place and install at this time Tighten the capscrews evenly Refer to FIGURE 4 for bearing housing assembly 6 Install the lip seal in the bearing housing See FIGURE 4 for lip orientation 7 Pack the ball bearing with grease and push or press the bearing into the bearing housing FIGURE 6 EXPLODED VIEW OF VIKING SERIES 4076 4176 PUMPS Pt lect o e rnes O S s Reload Sah Assembly OO 2 Bearno Spacer Colar Reqd 14 Pee OOOO S 2e erana Busing Asserbiy Co fenco is casing end Bushirgasseroy 2r fieri OO Uii 4 Linseal Reqg 16 ReiefVave Assembly 28 formon O Ts BalBeaing 17 Dovel Pin 2Req 176Sefes On faen SCS e Setsrew Rea 18 Foot 76 Series Ony 20 Head and Lube idler Pn Assembly 7 Bearing Housing 19 oowashers for Foot 4776 Series Ong 21 Pe Pug Hex Head 18 BSP ALE ATE e Setsrew Rea 20 Capscrens for Foot 4176 Seres On 32 O Ring For Jacketed Head Plate Oporal _ Co Nylon nsereReg 21 Re ate Gasket 2 Reqd on ATE BALE 38 Jaheted Head
15. sing Tighten each with equal force against the bracket The pump is now set with standard end clearance SECTION TSM 710 1 ISSUE C PAGE 6 OF 8 NOTE Be sure the shaft rotates freely If it doesn t repeat the above procedure 4 High viscosity liquids require additional end clearances The amount of extra clearance depends on the viscosity of the liquid pumped For specific recommendations consult the factory Table 3 shows the bearing housing adjustment required for additional end clearance as well as values for standard end clearance LENGTH ON OD mm FOR EACH 025 mm ADDITIONAL STANDARD END CLEARANCE Turn bearing housing CCW this distance to obtain either standard or additional end clearance TABLE 3 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 cracks easily If cracked the bushing will quickly disintegrate Using a lubricant on the bushing and the mating part will help in installation The additional precautions listed below must be followed for proper installation 1 Apress must be used for installation 2 Be certain the bushing is straight 3 Do not stop the pressing operation until the bushing is in the proper position starting and stopping will result in a cracked bushing 4 Check the bushing for cracks after installation INSTALLATION OF FOOT Series 4176 pumps com
16. struction may cause damage SECTION TSM 710 1 BEFORE opening any liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc be sure that e Any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections The pump drive system means motor turbine engine etc has been locked out or otherwise been made non operational so that it cannot be started while work is being done on the pump 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 BEFORE operating the pump be sure all drive guards are in place 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 DO NOT exceed the pumps rated pressure speed and temperature or change the system duty parameters from those the pump was originally supplied without confirming its suitability for the new service BEFORE operating the pump be sure that e Itis clean and free from debris e all valves in the suction and discharge pipelines are fully opened All piping connected to the pump is fully supported and correctly aligned with
17. umber and serial number are on the nameplate This manual deals only with Viking 4076 4176 pumps Specifications and recommendations are listed in Catalog Section 710 UNMOUNTED PUMP UNITS FIGURE 2 Flange Foot Units are designated by the un Model ALE 4076 Mounted Mounted mounted pump model numbers Shown with relief valve on pump casing followed by a letter indicating and flange mounting M Drive HLE4076 HLE4176 drive style M Horizontal with bracket ATE4076 ATE4176 D Direct Drive R Viking Reducer Drive ALE4076 ALE4176 P Commercial Reducer Drive TABLE 1 CORPORATION 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 PUMP 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 Warning In addition to possible serious Symbol Danger Failure to follow the indicated injury or death failure to follow the Legend a may result lin serious Injury indicated in
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