TECHNICAL SERVICE MANUAL
Contents
1. H 115 HX4 115 SECTION 2 BULLETIN TSM 115 V ISSUE B 4 03 2009 VIKING PUMP P O Box 398 661 Grove Ave Windsor Ontario N9A 6M3 Canada FLUID amp METERING 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 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 Viking 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 Th2. Do not over grease Applications involving very high or low temperatures will require other types of lubrication Consult factory with specific 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 5 and Assembly page 6 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 Figure 3 Left Hand Pump STORAGE If pump is to be stored or not used for six months or more pump must be drained and light coat of lubricant and rust preventative suitable to the application must be applied to all internal pump parts Lubricate fittings and apply a rust preventative to the shaft Viking suggests rotating pump shaft by
3. Continue with step 8 of the Packed Pump Assembly 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 Use soapy water as 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 Lubricate the bushing and bore with soapy water 3 Be certain bushing is started straight 4 Do not stop pressing operation until bushing is in proper position Starting and stopping will result in a cracked bushing 5 Check bushing for cracks after installation BUSHING Materials Viking bushing material recommendations Figure 15 Ball bearing retainer and Material Appearance Tnstalation Creating bracket Bronze Yellowish Not required Required Carbon Black Soapy Water Not required Iron Steel Oil or anti seize Required Nitralloy Steel Required Tungsten Steel Not required Figure 16 Pump ready for adjustment END CLEARANCE ADJUSTMENT 1 Loosen the setscrews in the inner race of the ball bearing Figure 18 2 Use Feeler gauges to set the distance between the rotor and the idler pin Put the gage through a port between the rotor and th
4. Remove idler and bushing assembly from the idler pin Remove the packing gland fastener and pull the gland out of the stuffing box and off of the shaft Tap the shaft forward with a softheaded hammer and pull it out of the casing and bushing assembly 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 bracket mounting surface 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 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 9 stand the unit on the head mounting surface and push the bushing out with a round bar through the packing end of the casing Figure 9 Gland amp shaft installed ASSEMBLY OF PACKED PUMPS Viking supplies pumps with a wide variety of bushing materials These materials should not a
5. hand one complete revolution every 30 days to circulate the oil SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 115 pumps These tools are in addition to standard mechanics tools such as open end wrenches pliers screwdrivers etc Most of the items can be obtained from an industrial supply house 1 Soft Headed hammer 2 Allen wrenches some mechanical seals and set collars 3 Packing hooks flexible packed pumps Small for 0 25 inch and 0 31 inch 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 This can cause 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 Figure 4 Idler bushing press fit Fiqure 5 Pressing the idler pin Se Figure 6 Casing bushing orientation PACKED PUMPS ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Bearing retainer bolts 9 Packing rings 17 ldler and bushing ass
6. 2 Bearing retainer 10 Casing bushing 18 Head gasket 3 Ball bearing 11 Casing 19 Idler pin 4 Bracket bolts 12 Casing and bushing assy 20 Head 5 Grease fitting 13 Grease fitting 21 Head and idler pin ass y 6 Bracket 14 Rotor and shaft ass y 22 Head Bolts 7 Packing gland fasteners 15 idler 8 Packing Gland 16 idler bushing Packed cross section Z1 P DAESSN M DI i 2 8 10 ti 12 13 ISASSEMBLY OF PACKED PUMPS Loosen the setscrews in the ball bearing inner race Remove the grease fitting from the casing Remove the Bracket fasteners from the casing Pull the casing with all components out of the bracket and bearing Remove the bearing retainer and pull the ball bearing out of the bracket 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 11 The gaskets must be totally removed Use new gasket when assembling pump
7. Mechanical seal is damaged or misaligned Shaft is scored Shaft is bent 12 PUMP INSPECTION REPORT DATE PUMP MODEL SERIAL NUMBER CUSTOMER SALES ORDER NUMBER OTHER REFERENCE APPLICATION AND OR PROBLEM DESCRIPTION STANDARD EX CL IF ACTUAL WEAR DIMENSIONS ANY ROTOR O D ROTOR LD ROTOR TOOTH LENGTH IDLER O D IDLER BUSHING I D IDLER TOOTH LENGTH IDLER PIN O D SHAFT O D SHAFT BUSHING LD CRESCENT LENGTH CASING LD END CLEARANCE COMMENTS amp RECOMMENDATIONS Notes FLUID amp METERING TECHNICAL SERVICE MANUAL section2 GENERAL PURPOSE BRACKET MOUNTED PUMPS BULLETIN TSM 115 V SERIES 115 SIZES H AND HX4 ISSUE B 4 03 2009 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 If during said warranty period any products sold by Viking prove to be defective in workmanship or material under normal use and service and if such products are returned to Viking s factory at Windsor Ontario tr
8. VIKING TECHNICAL SERVICE MANUAL PUMP CANADA GENERAL PURPOSE BRACKET MOUNTED PUMPS SERIES 115 MODELS H and HX4 CONTENTS Special Information 2 Maintenance 2 Packed Pump Breakdown Drawing 4 Packed Pump Disassembly 5 Packed Pump Assembly 6 Sealed Pump Breakdown Drawing 7 Sealed Pump Disassembly 8 Sealed Pump Assembly 8 Installation of Carbon Graphite Bushings 9 End Clearance Adjustment 10 Pneumatic Test 10 Pressure Relief Valve Instructions n Pressure Adjustment 11 Troubleshooting 12 Inspection Form 13 Notes 14 Warranty 15 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 number and serial number are on the nameplate In the Viking model number system basic size letters are combined with series number This manual deals only with Series 115 General Purpose Bracket Mounted Pumps Pump specifications and recommendations are listed in Catalog Section 2 Series 115 General Purpose Pumps UNITS UNMOUNTED PUMP Units are designated by the lunmounted pump model numbers followed by Arrangement indicating drive style H 315 HX4 115 jo 13 Direct Connected 53 V Belt Drive 70 Commercial Speed Reducer
9. ansportation charges prepaid and if the products are found by Viking to be defective in Workmanship or material they will be replaced or repaired free of charge FOB Windsor Ontario Viking 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 of Viking products by the purchaser his employees or others Viking will assume no field expense for service or parts unless authorized by itin advance Equipment and accessories purchased by Viking from outside sources which are incorporated into any Viking product are warranted only to the extent of and by the original manufacturer s 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 Canada is authorized to alter this warranty VIKING PUMP P O Box 398 661 Grove Ave Windsor Ontario N9A 6M3 Canada
10. be required Suction lift is too great Relief valve is stuck open Strainer needs cleaning Wrong direction of rotation Insufficient Discharge Volume 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 Insufficient Pressure 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 Loss of suction after a period Of operation Suction line is leaking letting air into the pump Packing is too loose or the mechanical seal is leaking Leaking Gaskets Excessive power requirement 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 Performance Misalignment of coupling Worn bearings Noisy operation with poor or No performance Cavitation Not enough fluid getting to the pump Worn bearings or bushings Leaking around the shaft Packing is loose or needs replacement
11. e idler deep enough to pass the pin Figure 17 3 Push the shaft into the pump by hand until the Feeler gauge starts to become clamped but can still be remove 4 Tighten the setscrews onto the shaft Figure 18 and remove the Feeler gauge 5 Check the rotation of the shaft There should be no contact between the rotor and the head Figure 17 Setting the end clearance PNEUMATIC TESTING 1 Seal the ports with pipe plugs Be sure to provide a male air line connection to one of the ports 2 Apply approximately 50 psi of air pressure to the pump 3 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 Figure 19 4 Relieve the pressure from the pump 5 Carefully disconnect the air supply 6 Remove the plugs or covers from the ports 7 Return the pump to service Grease Fitti acc Grease Fitting Bearing Retainer Ball Bearing c j Figure 19 Pneumatic testing Figure 22 Bearing Cross section 10 PRESSURE RELIEF VALVE INSTRUCTIONS DISASSEMBLY Mark valve and head before disassembly to insure proper reassembly 1 Be Ny Remove bonnet Measure and record length of adjusting screw protruding out of the end cap Loosen locknut and back out adjusting screw until spring pressure is released Remove relief valve cap sprin
12. eal seat retainer fasteners_ 16 Grease fitting 25 Head Bolts 8 Seal seat retainer 17 Rotor and shaft ass y 9 Retainer o ring 18 ider Mechanical Seal Cross Section N UNA Rotor Casing Bushing Driving Ring Rotating Seat Stationary Seat Pipe Plug Spring Seal Seat Retainer DISSASSEMBLY OF SEALED PUMPS Repeat steps 1 through 7 under DISASSEMBLY OF PACKED PUMP Page 5 1 Remove the fasteners from the seal seat retainer and pull it away from the seal chamber to free the spring on the seal and remove it 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 13 3 Remove the rotary member of seal and the driving ring from the bracket The stationary seal seat can be gently pried out of the retainer with a small flat screwdriver 4 Tap the shaft forward and remove the rotor and shaft assembly from the casing and bushing assembly 5 The bracket bushing can also be inspected while still in the casing If replacement is necessary stand the unit on the head mounting surface and push the bushing out with a round bar through the packing end of the casing 6 Clean all parts thoroughly and examine for wear or damage Check all parts for nicks burrs excessive wear and replace if necessary 7 Check the bearings for roughness Roughness can be determ
13. ere 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 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 always 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 2 possible configurations both have side suction and top discharge A right hand pump ums in the opposite direction to the left hand pump i 5 Pressure relief valves cannot be used to control pump flow or regulate discharge pressure Figure 1 Head orientation 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 115 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 Figure 2 Right Hand Pump LUBRICATION External lubrication must be applied slowly with a handgun to all lubrication fittings every 500 hours of operation with multi purpose grease
14. g guide spring and poppet from valve body Clean and inspect all parts for wear or damage and replace as necessary ASSEMBLY Reverse procedures outlined under Disassembly If valve is removed for repairs be sure to replace in same 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 pressure setting of pressure relief valve is to be changed from that which the factory has set the following instructions must be carefully followed i ae ep Carefully remove the bonnet which covers the adjusting screw Loosen the locknut which locks the adjusting screw so that the pressure setting will not change during operation of pump Install a pressure gauge in discharge line for actual adjustment operation Turn adjusting screw in to increase pressure and out to decrease pressure Closing a valve in the piping stopping all flow the 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 In ordering parts for pressure relief valve always give the name of the part model number and serial number of pump as it appears on nameplate When ordering springs be sure to give pressure setting desired 1 Troubleshooting No Discharge Pump priming may
15. ined by turning the inner and outer race opposite directions by hand Note if the motion is smooth and free or rough and stiff Smooth and free is desired ASSEMBLY OF SEALED PUMPS The seal used in this pump is simple to install and good performance will result if care is taken during installation A mechanical seal keeps liquid inside the pump by having to polished faces that contact One face is sealed to the shaft with an elastomer and rotates with the shaft The other face is sealed to the casing which is stationary These faces are lapped to a high finish and their sealing effectiveness depends on complete contact A number of heavy duty pumps with special mechanical seals are supplied These special seals are not discussed in TSM 115 Information is available by contacting the factory When requesting special seal information be sure to give pump model number and serial number Also a wide variety of bushing materials are used These materials should not all be treated the same See Bushing Materials page 9 1 Repeat steps 1 through 4 of Packed Pump Assembly Page 6 2 Press the stationary seat into the seal seat retainer while protecting the face as pictured in figure 11 3 Clean the casing seal housing bore and the shaft Make sure both are free from dirt and grit Coat the inner diameter of the seal housing bore and the shaft with a lubricant as recommended by your seal supplier 4 Put the shaft through the casing b
16. ing while turning counter clockwise slowly push the shaft through the packing Continue until the rotor and shaft assembly cannot move any further 8 Install the head and idler assembly on pump with two casing gaskets between them Figure 10 If the pump head and casing were marked before disassembly simply match up the markings If not be sure the idler pin which is offset in pump head is positioned belween the ports Tighlen head cap screws evenly Figure 1 page 2 shows the appropriate orientation to the ports 9 Install the bearing into the bracket 10 Replace the bearing retainer onto the bracket with the small step away from the bearing figure 15 page 10 11 Install the pump and components into the bracket and bearing assembly figure 16 page 9 12 Replace the grease fittings and pipe plugs 13 Adjust pump end clearance Refer to End Clearance Adjustment page 11 14 Lubricate all grease fittings with multi purpose grease Figure 10 Mounting the head MECHANICAL SEAL PUMPS ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Bearing retainer bolts 10 Mechanical seal ass y 19 idler bushing 2 Bearing retainer 11 Driving Ring 20 ldler and bushing ass y 3_ Ball bearing 12 Casing bushing 21 Head gasket 4 Bracket bolts 18 Casing 22 ldler pin 5 Grease fitting 14 Casing and bushing ass y 28 Head 6 Bracket 15 Pipe plug 24 Head and idler pin ass y 7 S
17. ll be treated the same See Bushing Materials page 9 1 Press the idler bushing into the idler gear figure 4 page 3 Refer to Installation of Carbon Graphite Bushing see page 9 2 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 3 Coat idler pin with non detergent SAE 30 weight oil and place idler and bushing on idler pin in the head If replacing with carbon graphite bushing refer to Installation of Carbon Graphite Bushings page 9 4 Install the casing bushing If the bushing has a lubrication groove install bushing with the lubrication hole aligned with the grease fiting hole on the casing Figure 6 page3 If carbon graphite refer to Installation of Carbon Graphite Bushings page 9 5 Use only new packing suitable for the liquid being pumped Install the packing staggering the joints from one side of shaft to other Figure 7 page 5 If needed lubricate packing rings with oil grease or graphite to aid assembly A length of pipe will help to seat each packing ring Figure 8 page 5 6 Install packing gland cap screws and nuts Make sure the gland is installed square and nuls are loose Figure 9 Refer to Packing Adjustment page 2 after the pump is assembled and installed 7 Coat the shaft of the rotor and shaft assembly with non detergent SAE 30 weight oil Start the end of shaft in the casing bush
18. ushing and rotor all the way into the casing 5 Install the head and idler assembly on pump with two casing gaskets between them Figure 10 page 6 If the pump head and casing were marked before disassembly simply match up the markings If not be sure the idler pin which is offset in pump head is positioned between the ports Tighten head cap screws evenly Figure 1 page 2 shows the appropriate orientation to the ports 6 Place the spring on driving ring and with the setscrews already started in the threads of the driving ring Put the spring and ring on the shaft 7 Slide rotary member lapped contact surface facing away from spring onto shaft until it is in the spring Figure 12 page 8 Figure 11 Installing the Seal al Figure 12 Installing the rotating seal components Figure 13 Setting the driving ring 8 Push the 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 and tighten down the two setscrews on the ring figure 13 page 8 9 Place the seal seat retainer with the stationary seat facing the seal chamber on the shaft 10 Check that the retainer is centered and square with the shaft 11 Tighten the fasteners evenly and in small increments figure 14 12 Replace the pipe plug in the hole in the side of the seal chamber 18
Download Pdf Manuals
Related Search