TECHNICAL SERVICE MANUAL
Contents
1. 1 Viking pumps are positive displacement pumps and must be provided wth 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 to tank relief valve and a jacketed relief valve Pumps equipped with a jacketed head plate are generally 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 adjusting screw cap must always poini towards suction side of pump If pump rotation is reversed remove pressure relief valve and turn end for end Refer to Figure 5 5 Pressure relief valves should not be used to contro pump flow or regulate discharge pressure For additional information on pressure relief valves refer to Technical Service Manual TSM 000 and Engineering Service Bulletin ESB 31 SPECIAL MECHANICAL SEALS This bulletin illustrates the mechanical seal which is standard in the catalog pump A Seal Installation Drawing will be furnished with a pump fitted with a non standard mechanical seal Consult this Seal Installation Drawing before disassembling pump Modifications are required to install Teflon seals in these pumps Contact factory for specific information re RELIEF VALVE ADJUSTI2. LIST OF PARTS position Relief valve adjusting screw cap must always 1 Valve Cap 6 Valve Body point towards suction side of pump If pump rotation is 2 Adjusting Screw 7 Valve Spring reversed remove relief valve and turn end for end Refer to Figures 5 page 2 3 Lock Nut 8 Poppet 4 Spring Guide 9 Cap Gasket 5 Bonnet 10 Bonnet TECHNICAL SERVICE MANUAL VIKING HEAVY DUTY PUMPS ee z SERIES 4195 and 495 PUMP SERIES GG AL DANGER BEFORE STARTING PUMP BE SURE ALL DRIVE EQUIPMENT GUARDS ARE IN PLACE FAILURE TO PROPERLY MOUNT GUARDS MAY RESULT IN SERIOUS INJURY OR DEATH PRESSURE ADJUSTMENT If a new spring is installed or if pressure setting of pressure relief valve is to be changed from that which the factory has set the following instructions must be carefully followed 1 Carefully remove valve cap which covers adjusting screw Loosen locknut which locks adjusting screw so pressure setting will not change during operation ol pump 2 Install a pressure gauge in discharge line for actual adjustment operation 3 Turn adjusting screw in to increase pressure and out to decrease pressure 4 With discharge line closed at a point beyond pressure gauge gauge will show maximum pressure valve will allow while pump is in operation IMPORTANT In ordering parts for pressure relief valve always give model number and serial number of pump as it appears on nameplate and name of part wanted When ordering springs b
3. NG SCREW CAP SUCTION DISCHARGE FIGURE 5 MAINTENANCE Series 4195 and 495 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 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 f pump is to be stored or not used for six months or more pump must be drained and a light coat of nondetergent SAE 30 weight oil must be applied to all internal pump parts Lubricate fittings and apply grease to pump shaft extension Viking suggests rotating pump shaft by hand one complete revolution every 30 days to circulate the oil SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 4195 and 495 pumps These tools are in addition to standard mechanics tools such as open end wrenches pliers screw drivers etc Most of the items can be obtained from an industrial supply house 1 Soft Headed hammer 2 Allen wrenches set screws amp special mechanical seals 3 Snap Ring Pliers INTERNAL Viking Part No 2 810 047 999 GG HJHL 4195 495 EXTERNAL Viking Part No 2 810 029 375 GG HJHL 4195 495 4 Mechanical Seal Installation Sleeve 2 751 001 900 for 0 75 inch seal GG 4195 495 2 751 004 900 for 1 25 inch seal AS AL 4195 495 5 B
4. OR DEATH THRUST BEARING ADJUSTMENT See Figures 9 and 10 Loosen two screws in face of thrust bearing assembly lf shaft cannot be rotated freely turn thrust bearing assembly counterclockwise until shaft can be turned easily To set end clearance 1 While turning rotor shaft rotate thrust bearing assembly clockwise until noticeable drag occurs This is zero end clearance Mark position of bearing housing with respect to the casing Rotate thrust bearing assembly counterclockwise the distance listed below as measured on outside of bearing housing Tighten two setscrews in face of bearing housing after adjustment is made to secure thrust bearing assembly position For viscosities above 2500 SSU add additional end clearance 0 004 for GG HJ and HL size pumps and 0 005 for AS AK and AL size pumps Distance In Inches On End O D Of Bearing Housing Clearance 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 easily cracked If cracked the bushing will quickly disintegrate Using a lubricant and adding a chamfer on the bushing and the mating part will help in installation The additional precautions listed below must be followed for proper installation 1 Apress must be used for installation 2 Be certain bushing is started straight 3 Do not stop pressing operation until bu
5. SERIES 4195 and 495 PUMP SERIES GG AL SECTION TSM 144 PAGE 1 ISSUE B FIGURE 1 GG HJ and HL 4195 SERIES Foot Type Unmounted Pump with Tapped we i FIGURE 2 AS AK and AL 4195 SERIES Foot Type Unmounted Pump with Tapped Ports FIGURE 3 GG HJ and HL SIZE 495 SERIES Unmounted Pump with Tapped Ports FIGURE 4 AS AK and AL SIZE 495 SERIES Unmounted Pump with Tapped Ports SPECIAL INFORMATION DANGER BEFORE OPENING ANY VIKING PUMP LIQUID CHAMBER PUMPING CHAMBER RESERVOIR RELIEF VALVE ADJUSTING CAP FITTING ETC BE SURE 1 THAT ANY PRESSURE IN CHAMBER HAS BEEN COMPLETELY VENTED THROUGH SUCTION OR DISCHARGE LINES OR OTHER APPROPRIATE OPENINGS OR CONNECTIONS 2 THAT THE DRIVING MEANS MOTOR TURBINE ENGINE ETC HAS BEEN LOCKED OUT OR MADE NON OPERATIONAL SO THAT IT CANNOT BE STARTED WHILE WORK IS BEING DONE ON PUMP 3 THAT YOU KNOW WHAT LIQUID THE PUMP HAS BEEN HANDLING AND THE PRECAUTIONS NECESSARY TO SAFELY HANDLE THE LIQUID OBTAIN A MATERIAL SAFETY DATA SHEET MSDS FOR THE LIQUID TO BE SURE THESE PRECAUTIONS ARE UNDERSTOOD FAILURE TO FOLLOW ABOVE LISTED PRECAUTIONARY MEASURES MAY RESULT IN SERIOUS INJURY OR DEATH ROTATION Viking pumps operate equally well in a clockwise or counterclockwise rotation Shaft rotation determines which port is suction and which is discharge Suction Port is where pumping elements gear teeth come out of mesh PRESSURE RELIEF VALVES
6. TECHNICAL SERVICE MANUAL VIKING CONTENTS Introduction Special Information Special Mechanicd Seals Maintenance Disassembly Assembly Thrust Bearing Adjustment Installation of Carbon Graphite Bushings Pressure Relief Valve Instructions INTRODUCTION The illustrations used in this manual are for identification purposes only and cannot be used for ordering parts Obtain a parts list from the factory or a Viking representative Always give complete name of part part number and material with model number and serial number of pump when ordering repair parts The unmounted pump or pump unit model number and serial number are on the nameplate secured to the pump NNN OWONMN ND In the Viking model number system basic size letters are combined with series number 4195 and 495 indicating both the unmounted or mounted pump units Model Number Chart CUNMOUNTEDPUMP NTS Units Are Designed By The Un Mounted Pump Model Numbers Followed By A Letter s Indicating Drive Style as D Direct Drive M Horizontal Direct Drive IM Vertical In Line Direct Drive This manual deals only with Series 4195 and 495 Heavy Duty Pumps Refer to Figures 1 thru 14 for general configuration and nomenclature used in this manual Pump specifications and recommendations are listed in Catalog Section 144 Series 4195 and 495 Heavy Duty Pumps IREX VIKING PUMP INC DEX CORPORATION A Unit of IDEX Corporation HEAVY DUTY PUMPS
7. acing a carbon graphite bushing refer to Installation of Carbon Graphite Bushings page 7 2 Clean rotor hub and casing seal housing bore Make sure both are free from dirt and grit Coat outer diameter of seal seat and inner diameter of seal housing bore with non detergent SAE 30 weight oil 3 Start seal seat in seal housing bore If force is necessary protect seal face with a clean cardboard disc and gently tap i1 in place with a piece of wood Be sure seal seat is completely seated in the bore SPRING MECHANICAL SEAL ROTARY MEMBER TAPERED SLEEVE COAT WITH LIGHT OIL BEFORE ASSEMBLY FIGURE 11 MECHANICAL SEAL ROTARY MEMBER SHAFT FIGURE 12 Place tapered installation sleeve on shaft refer to Figure 11 Sleeve is furnished with GG AS AK and AL replacement mechanical seals Coat rotor shaft tapered installation sleeve and inner diameter of mechanical seal rotary member with a generous amount of non detergent SAE 30 weight oil Petrolatum may be used but grease is not recommended Place seal spring on shaft against rotor hub Refer to Figure 12 Slide rotary member lapped contact surface facing away from spring over installation sleeve on shaft until just contacting the spring Do not compress spring Remove installation sleeve Coat rotor shaft with non detergent SAE 30 weight oil Install shaft slowly pushing until the ends of rotor teeth are just below the face of the casing Leave the roto
8. al Seal Consult the factory FIGURE 8 EXPLODED VIEW MODELS AS AK and AL 4195 and 495 NAME OF PART NAME OF PART NAME OF PART NAME OF PART Bearing Spacer Relief Valve Idler and Bushing Bearing Spacer Collar 8 Ball Bearing Inner Pipe Plug Head Gasket 3 End Cap for Bearing Housing 9 Bearing Retainer Washer 14 Cansctew tor Vawe 20 lderPin 6 Bearing Housing 11 _ Gasketfor Relief Vawe 17 Idler Bushing 23 Capscrew Tor Head Teflon Registered Trademark of DuPont Dow Elastomers L L C 4 INNER BALL BEARING BALL BEARING OUTER SNAP RING ee LOCKNUT BEARING HOUSING BALL BEARING INNER SNAP RING d PA FIGURE 9 THRUST BEARING ASSEMBLY GG HJ and HL SIZES BALL BEARING SETSCREW NYLON INSERT END CAP LIP SEAL awk 1 fa a a u A 7 LOCKNUT EEEN BEARING HOUSING oa SETSCREW iii ZAE S rT E r erak INNER BALL BEARING erie By ___ BEARING RETAINER WASHER 7 FIGURE 10 THRUST BEARING ASSEMBLY AS AK and AL SIZES 10 The rotor and shaft can now be removed by tapping on end of shaft with a lead hammer or if using a regular hammer use a piece of hardwood between shaft and hammer The rotary member of the seal will come out with rotor and shaft 11 AS AK AL Remove bearing retainer washer The washer may have stayed with Rotor and Shaft when removed or is against ball bearing See Figu
9. cer over shaft and against single row ball bearing See Figure 10 14 Pack lubrication chamber between inner ball bearing and double row ball bearing in the thrust bearing assembly approximately one half full of multi purpose grease NLGI 2 The thrust bearing assembly will take the remaining space See Figure 9 and 10 15 Pack double row ball bearing with multi purpose grease NLGI 2 GG HJ HL Install ball bearing into bearing housing with shield side toward coupling end of shaft See Figure 9 Install snap ring into bearing housing to retain ball bearing This snap ring has a tapered edge to fit tapered groove in bearing housing The tapered edge is located away from ball bearing AS AK AL Install ball bearing into bearing housing Install lip seal in bearing housing end cap The lip should face towards end of shaft Put bearing spacer collar in lip seal and install in bearing housing and tighten set screws securely See Figure 10 16 Insert brass bar or hardwood through port opening betw een rotor teeth to keep shaft from turning 17 Start thrust bearing assembly into casing Turn by hand until tight This forces rotor against head Replace and tighten locknut or shaft 18 Remove brass bar or hardwood from port opening 19 Adjust pump end clearance refer to page 7 DANGER BEFORE STARTING PUMP BE SURE ALL DRIVE EQUIPMENT GUARDS ARE IN PLACE FAILURE TO PROPERLY MOUNT GUARDS MAY RESULT IN SERIOUS INJURY
10. e sure to give pressure setting desired IREX VIKING PUMP INC DEX CORPORATION A Unit of IDEX Corporation SECTION TSM144 ISSUE B VIKING PUMP meni and accessories purchased by ING from outside sources which are incorporated into any Viking product are warranted only to the extent of and by the original manufacturers warranty or guarantee if any THIS IS VIKING S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED WHICH ARE HEREBY EXCLUDED INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE No officer or employee of IDEX Corporation or Viking Pump Inc is authorized to alter this warranty J Lj zi i ew VIKING PUMP INC Copyright 2000
11. earing Locknut Spanner Wrench Source 471 J H Williams amp Co or equal 6 Spanner Wrench adjustable pin type for use on bearing housing end cap Source 482 J H Williams amp Co or equal 7 Brass bar 8 Arbor press DISASSEMBLY 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 HEAD IDLER PRESSURE RELIEF VALVE IDLER PIN HEAD GASKET Refer to figures 7 amp 8 page 4 for model to be disassembled and name of parts Models 4195 amp 495 are disassembled and assembled the same The difference between these models is the casings Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in the pump head must be positioned up an equal distance between port connections to allow for proper flow of liquid through the pump Remove the head capscrews NOTE The four valve capscrews valve and gasket must be removed from the GG 4195 495 model before the six head capscrews are removed Tilt top of head back when remo
12. ness Roughness can be determined by turning outer race by hand Replace bearings if bearings have roughness Be sure shaft is free from nicks burrs and foreign particles that might damage mechanical seal Scratches on shaft in seal area will provide leakage paths under mechanical seal Use fine emery cloth to remove scratches or sharp edges ASSEMBLY Assembly Notes On Standard Mechanical Seal Synthetic Rubber Bellows Type READ CAREFULLY BEFORE REASSEMBLING PUMP The seal used in this pump is simple to install and good performance will result if care is taken during installation The principle of mechanical seal is cmtact between the rotary and stationary members These parts are lapped to a high finish and their sealing effectiveness depends on complete contact Prior to installing rotary portion of mechanical seal prepare and organize rotor shaft head and idler assemblies and appropriate gaskets for quick assembly Once rotary portion of mechanical seal is installed on rotor shaft it is necessary to assemble parts as quickly as possible to insure the seal does not stick to shaft in wrong axial position The seat will stick to the shaft after several minutes setting time Never touch sealing faces with anything except clean hands or clean cloth Minute particles can scratch the seal faces and cause leakage 1 Coat idler pin with non detergent SAE 30 weight oil and place idler and bushing on idler pin in head If repl
13. r in this position Withdrawal of rotor and shaft may displace the carbon seal rotating face and result in damage to the seal Place O ring gasket on head and install head and idler assembly on pump Pump head and casing were marked before disassembly to insure proper reassembly If not be sure idler pin which is offset in pump head is positioned up and equal distance between port connections to allow for proper flow of liquid through pump 10 Tighten head capscrews evenly 11 If pump was equipped with a relief valve and was removed during disassembly install on head with new gaskets Relief valve adjusting screw cap must always point towards suction port Refer to Figure 5 page 2 For relief valve repair or adjustments see PRESSURE RELIEF VALVE INSTRUCTIONS Page 7 12 Pack inner ball bearing with multi purpose grease NLGI 2 GG HJ HL Install bearing in casing with sealed side towards head end of pump Drve the bearing into the bore Tap the inner race with a brass bar and lead hammer to position bearing Install inner snap ring AS AK AL Install bearing retainer washer over the shaft before installing ball bearing Install ball bearing in casing with sealed side towards head end of pump Drive the bearing into the bore Tap the inner race with a brass bar and lead hammer to position bearing 13 GG HJ HL Install shaft snap ring in groove in the shaft See Figure 9 AS AK AL Install bearing spa
14. re 10 12 Remove the mechanical seal rotary member and spring from rotor and shaft assembly 13 GG HJ HL AS AK AL Remove inner snap ring and single row ball bearing from casing Remove single row ball bearing from casting 14 Remove seal seat or stationary part of seal from casing 15 Disassemble thrust bearing assembly GG HJ HL AS AK AL Remove outer snap ring from bearing housing and remove ball bearing See Figure 9 Loosen two set screws in flange outside diameter Rotate end cap and lip seal counterclockwise and remove Remove ball bearing See Figure 10 The casing should be examined for wear particularly in the area between ports All parts should be checked for wear before pump is put together When making major repairs such as replacing a rotor and shaft it is advisable to also install a new mechanical seal head and idler pin idler and bushing See Installation of Carbon Graphite Bushings page 7 Clean all parts thoroughly and examine for wear or damage Check lip seals ball bearings bushing and idler pin and replace if necessary Check all other parts for nicks burrs excessive wear and replace if necessary Wash bearings in clean solvent Blow out bearings with compressed air Do not allow bearings to spin turn them slowly by hand Spinning bearings will damage race and balls Make sure bearings are clean then lubricate with non detergent SAE 30 weight oil and check for rough
15. shing is in proper position starting and stopping will result in a cracked bushing 4 Check bushing f cracks after installation PRESSURE RELIEF VALVE DISASSEMBLY INSTRUCTIONS DQ O OOOT k ZZE atl SHH HH Perl iin Ls OPERATIONAL SO THAT IT CANNOT BE STARTED WHILE WORK IS BEING DONE FIGURE 13 ON PUMP VALVE GG HJ and HL SIZES 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 we UM MAAIL ERA K VALVE LIST OF PARTS Valve Cap 6 Valve Body Adjusting Screw Valve Spring 7 Lock Nut 8 Poppet 9 Cap Gasket Spring Guide Bonnet Mark valve and head before disassembly to insure proper reassembly 1 Remove valve cap 2 Measure and record length of extension of adjusting screw Refer to A on Figures 13 and 14 3 Loosen locknut and back out adjusting screw until spring pressure is released 4 Remove bonnet spring guide spring and poppet from valve body Clean and inspect all parts for wear or damage and replace as necessary FIGURE 14 ASSEMBLY VALVE AS AK and AL SIZES Reverse procedures outlined under Disassembly If valve is removed for repairs be sure to replace in same VALVE
16. ving to prevent idler from falling off idler pin Remove idler and bushing assembly If idler bushing needs replacing see Installation of Carbon Graphite Bushings page 7 Insert a brass bar or piece of hardwood in the port opening and between the rotor teeth to keep the shaft from turning Turn the locknut counterclockwise and remove locknut See Figure 9 or 10 Loosen two setscrews in face of bearing housing and turn thrust bearing assembly counterwise and remove from casing See Figure 9 or 10 GG HJ HL Remove snap ring from shaft See Figure 9 AS AK AL Remove bearing spacer from shaft See Figure 10 Remove brass bar or piece of hardwood from port opening MECHANICAL SEAL BALL BEARINGS SHAFT SNAP RINGS CASING FIGURE 6 CUTAWAY OF MODELS GG Hu or HL 4195 Modifications to pump casing and rotor are required for installation of optional Teflon Mechanical Seal Consult the factory FIGURE 7 EXPLODED VIEW MODELS GG HJ and HL 4195 and 495 Cra tore D 2 Snap Ring Outer BEN EA 5 n eren r eea e e 2 i e Casma 13 ider ard Bushing 19 Relief vave 3 4 Snap Ring for Sha 9 PipePug s fem O 5 Bearing Housing 10 Mechanica Sea 16 Pedana O OO 6 Snap Ring Inner Rotor and Shaft Capscrew for Head a NOT USED ON GC SIZE PUMPS BsEy5e Modifications to pump casing and rotor are required for installation of optional Teflon Mechanic
Download Pdf Manuals
Related Search