TECHNICAL SERVICE MANUAL
Contents
1. VIKING PUMP CAMADA MODELS J K KK L LO LL AND LM CONTENTS TECHNICAL SERVICE MANUAL J sections BULLETIN TSM 120 124 V HEAVY DUTY BRACKET MOUNTED PUMPS ISSUE B 2005 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 9 Installation of Carbon Graphite Bushings 10 End Clearance Adjustment 10 Pressure Relief Valve Instructions 11 Pneumatic Testing 11 Pressure Adjustment 12 Troubleshooting 13 Pump Inspection Report 14 Notes 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 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 LL 124 Shown with 180 Deg Ports UNMOUNTED PUMP UNITS Units are designated by the unmounted pump model numbers followed by Arrangement indicating drive style 13 Direct Connected LL 124 53 Belt Driven LM 124 70 Commercial Speed Reducer 90 Commercial Gear Motor This manual deals only with Series 120 and 124 Heavy Duty Bracket Mount2. 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 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 Excessive power requirement 13 PUMP INSPECTION REPORT PUMP MODEL CUSTOMER SALES ORDER NUMBER APPLICATION AND OR PROBLEM DATE SERIAL NUMBER REFERENCE DESCRIPTION STANDARD EX CL ACTUAL WEAR mo canes ANY ROTOR O D O D To o I D ROTORTOOTHLENGTH 0 0 ooo o o y oo DLER O D E A S G IDLER BUSHING 1D IDLER TOOTH LENGTH IDLER PIN O D ISI T EEE SHAFT O D SHAFT BUSHING 1D CRESOENT LENGTH casna SSS s y S END OLEARANCE 3 COMMENTS amp RECOMMENDATIONS NOTES VIKING TECHNICAL SERVICE MANUAL sections PUT HEAVY DUTY BRACKET MOUNTED PUMPS BULLETIN TSM 120 124 V SERIES 120 and SERIES 124 ISSUE A 2004 CANADA SIZES J K KK L LQ LL AND LM MEX DEX CORPORA TIC IDEX CORPORATION VIKING PUMP A Unit of IDEX Corporation 661 Grove Ave Windsor Ontario N9A 6M3 Canada
3. Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Tighten the lock nut One tab of the lock washer will line up with a slot in the lock nut Bend that tab into the slot Figure 15 page 8 Put the outer end cap and lip seal assembly on the shaft and turn it into the bracket until itis against the bearing Place one casing gasket and the bracket on the casing Start the bolts into the casing threads Figure 16 page 8 Turn the shaft to determine if the rotor is rotating freely inside the casing If not tap the casing with a softheaded hammer until the rotor does not touch the casing Tighten the bolts evenly on the casing Install the head and idler assembly on pump with two casing gaskets between them 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 pin and crescent in the appropriate orientation to the ports Adjust pump end clearance Refer to End Clearance Adjustment page 10 Lubricate all grease fittings with multi purpose grease MECHANICAL SEAL PUMPS ITEM ITEM NAME OF PART 1 Lipseal Outer 9 SetScrews 17 Lo Bracket Bushing 6 Bearing Spacer____ 14 Seal Seat Retainer asing Gasket Exploded View for Mechanical Seal Models J 124 K 124 KK 124 L 124 LQ 12
4. grease 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 face 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 Figure 3 Left Hand 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 If 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 Rotating the pump shaft by hand one
5. appears on nameplate and name of part wanted When ordering springs be sure to give pressure setting desired PNEUMATIC TESTING 1 Seal the ports with pipe plugs or plates and gaskets Be sure to provide a male air line connection to one of the ports 2 Apply air pressure to the pump 3 Spray or brush the externals with soapy water and watch for growing air bubbles around the seal fitting and gaskets Figure 27 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 12 Troubleshooting 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 Loss of suction after a period Suction line is leaking letting air into the pump Of operation Packing is too loose or the mechanical seal is leaking Leaking Gaskets
6. relief valve a torque limiting device or a rupture disk 2 There are relief valve options available on pump models 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 see page 11 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 turns in the opposite direction to the left hand 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 124 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 LUBRICATION All pumps are greased at the factory External lubrication must be applied slowly with a grease gun to all lubrication fittings every 500 hours of operation with multi purpose
7. will provide leakage paths under mechanical seal Casing and bracket bushing can be checked for wear or damage while assembled If needed remove the bracket bushing with the casing still mounted by standing the unit on the casing in a press and proceed to push the bushing out of the bracket Figure 17 Head mounted Figure 14 Ball bearing unting the casing Figure 18 Tighten down t endcap he outer ASSEMBLY Standard Mechanical Seal The seal used in this pump is simple 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 Viking furnishes a number of heavy duty pumps with special mechanical seals These special seals are not discussed in TSM124 Information is available by contacting the factory When requesting special seal information be sure to give pump model number and serial number Viking supplies pumps with a wide variety of bushing materials These materials should not all be treated the same See Bushing Material page 10 1 Perform steps 1 through 4 of Packed Pump Assembly Never touch sealing faces with anything except clean hands or clean cloth Minute particles can scratch the seal faces and cause leakage 2 Press the stati
8. 4 LL 124 and LM 124 Model LL 124 shown Lip Seal Inner Retainer O ring Casing 1 Grease Fitting 8 End cap Inner Stationary Seal Seat Rotor and Shaft Ass y Setscrew g l Driving Stationary Rotating Spring Ring Element Element Spring eal Rotatina Member T i Tapered Installation Sleeve Coat the shaft tapered installation sleeve and inner diameter of mechanical seal with lubricant as recommended by your seal supplier DISSASSEMBLY 10 11 12 13 14 15 Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump head must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Remove head from pump Do not allow idler to fall from idler pin Tilt top of head back when removing to prevent this 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 gaskets when assembling a pump Remove idler and bushing assembly from the head and idler pin Loosen the setscrews on the end caps and remove the outer end cap only Figure 22 page 10 Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Bend up tab of lockwasher and remove the lock nut and lock washer from shaft Remove the fasteners
9. NT 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 l 2 TEM NAME OF PART 1 Bonnet 4 Bonneto ring 7 Cap Gasket 10 Poppet 2 Adjusting Screw____ 5 Endcap 8 Spring 11 Reliefvalve port gasket 3 llocknt____ 6 Spring Guide 9 Casing Remove bonnet Measure and record length of adjusting screw protruding out of the end cap Loosen lock nut and back out adjusting screw until spring pressure is released 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 Carefully remove the bonnet which covers the adjusting screw Figure 26 page 12 Loosen the lock nut which locks the adjusting screw so that the pressure setting will not change during operation of pump Figure 25 Page 12 Install a pressure gauge in discharge line for actual adjustment operation Figure 24 Spring amp Retainer Turn adjusting screw in to increase pressure and out to decrease pressure Closing a valve in the piping will stop 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 11 IMPORTANT In ordering parts for pressure relief valve always give model number and serial number of pump as it
10. ce and balls Make sure bearings are clean then lubricate with non detergent SAE 30 weight oil and check 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 Figure 10 11 The casing can be checked for wear or damage while mounted on the bracket 12 The bracket bushing can also be inspected while still in the bracket If replacement is necessary stand the unit on the casing and push the bushing out with a round bar through the bearing end of the bracket f i j the stuffing box ASSEMBLY Viking supplies pumps with a wide variety of bushing materials These materials should not all be treated the same See Bushing Material page 10 le 10 4 12 13 14 15 Press the idler bushing into the idler gear If carbon graphite refer to Installation of Carbon Graphite Bushings page 10 Figure 4 page 3 Using the idler and bushing assembly as a guide press the idler pin into the head with the tapped hole into the head and the lubrication hole or groove directed toward the center of the crescent on the head Figure 5 page 3 Press lip seals into the end caps figure 6 and 7 page 3 lip facing away from the threads Put the inner end cap in the bracket as shown in figure 11 Install the bracket bushing If bracket bushing has a lubrication groove install bushin
11. complete revolution every 30 days to circulate the oil SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 124 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 Large for 0 38 inch and up cross section packing 4 Mechanical seal installation sleeve 5 Bearing locknut wrench or hammer and punch 6 Spanner wrench adjustable pin type for use on end caps Source 482 J H Williams amp Co or equal or hammer and punch 7 Brass bar 8 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 i Figure 4 Idler bushing press fit 1R f Figure 7 Outer lipseal or
12. ed Pumps Pump specifications and recommendations are listed in Catalog Section 3 series 124 Heavy Duty Bracket Mounted Pumps IBEX IDEX CORPORATION VIKING PUMP A Unit of Idex Corporation 661 Grove Ave Windsor Ontario N9A 6M3 Canada 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 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 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
13. from the seal seat retainer and pull it away from the seal chamber to free the spring on the seal Remove the pipe plug from the bracket 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 Carefully tap the shaft forward and remove the rotor and shaft assembly from the pump Hold the seal seat retainer so that it does not fall and damage the stationary seat of the seal Remove the rotating seat of seal and the driving ring from the bracket The stationary seal seat can be removed from the seal seat retainer by gently prying the seal seat out with a small flat screwdriver Remove the inner end cap To remove the bearing from the bracket Tap the bearing forward with a soft headed hammer Clean all parts thoroughly and examine for wear or damage Check lip seals ball bearing 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 roughness Roughness can be determined by turning outer race by hand Be sure shaft is free from nicks burrs and foreign particles that might damage bracket bushing Scratches on shaft in seal area
14. g with the lubrication hole aligned with the grease fitting hole on the bracket Figure 8 page 5 If carbon graphite refer to Installation of Carbon Graphite Bushings page 10 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 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 10 page 5 Install packing gland cap screws and nuts Make sure the gland is installed square and nuts are loosely assembled Figure 12 Refer to Packing Adjustment page 2 after the pump is assembled and installed Coat the shaft of the rotor and shaft assembly with non detergent SAE 30 weight oil Start the end of shaft in the bracket bushing while turning counter clockwise slowly push the shaft through the packing Continue until the rotor and shaft assembly cannot move any further Slide bearing spacer over shaft past the threads and against the shoulder on the shaft Figure 13 With the ball bearing on the bench hold the grease gun tip against the bearing and apply grease to the top of the bearing all the way around the diameter Place the ball bearing on the shaft and push it against the bearing spacer See figure 14 page 8 Hold the grease gun tip against the bearing and apply grease to the top of the bearing as before Put the lock washer and lock nut on shaft
15. ientation PACKED PUMPS Exploded View for Packed Models J 124 K 124 KK 124 L 124 LQ 124 LL 124 and LM 124 Model LL 124 shown ITEM NAME OF PART ITEM NAME OF PART NAME OF PART Lip Seal Outer Rotor and Shaft Ass y End Cap Outer Pipe Plug Idler Bushing Packing Gland Fasteners Idler Pin Ball Bearing Packing Gland Casing Gasket 6 Bearing Spacer_________ 15 Packing Rings 8 EndCap 17 CasingGasket_________ 9 Setscrew_____________ 18 Casing AAA Packing area cross section Packing Rings DISASSEMBLY ll al q 8 Mark head and casing before disassembly to insure proper reassembly 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 18 page 9 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 remove it from the head and refer to Pressure Relief Valve Instructions page 11 The gaskets must be totally removed Use new gasket when assembling pump Remove idler and bushing assembly from the idler pin Loosen the setscrews on the bearing end of the bracket and remove the outer end cap Figure 22 page 10 Remove the packing gland fasteners Insert a length of hardwood or brass thro
16. onary seat into the seal seat retainer while protecting the face as pictured in figure 19 Prior to installing rotating portion of mechanical seal prepare and organize rotor shaft head and idler assemblies and appropriate gaskets for quick assembly Once rotating portion of mechanical seal is installed on rotor shaft it is necessary to assemble parts as quickly as possible to insure that seal does not stick to shaft in wrong axial position The seal should be expected to stick to the shaft after several minutes setting time 3 Clean the bracket 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 recommended by your seal supplier 4 Place the sleeve installation guide on the shaft 5 Start the end of shaft in the bracket bushing and slowly push the shaft through Continue until the shaft begins to emerge from the seal chamber 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 AE gi Figure 21 Tightening the seal 7 Slide rotary member lapped contact surface facing away from spring over installation sleeve on shaft until it is against spring Do not compress spring 8 Place the seal seat retainer with the stationary seat facing the seal chamber on the shaft Figure 20 page 9 9 Guide the rotating element past the
17. steps in the shaft and over the tapered guide Carefully push the rotor and shaft assembly all of the way into the bracket 10 Remove the tapered installation sleeve from the shaft 11 Do steps 8 through 14 of the Packed Pump Assembly 12 Push the spring into the seal chamber until the driving ring is visible through the tapped hole in the seal chamber Then turn the shaft until the setscrews can be tightened down 13 Push the seal assembly into the seal chamber and attach the fasteners loosely Figure 21 14 Check that the retainer is centered and square with the shaft 15 Tighten the fasteners evenly and in small increments 16 Replace the pipe plug in the hole on the side of the stuffing box 17 Pneumatic test your pump for leaks See Page 12 18 Lubricate all grease fittings with multi purpose grease 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 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 Star
18. ting and stopping will result in a cracked bushing 5 Check bushing for cracks after installation BUSHING MATERIALS Viking bushing material recommendations Lubricant Lubrication Nitralloy Not required Figure 22 Loosening the set screws END CLEARANCE ADJUSTMENT 1 Loosen setscrews over outer and inner end caps Figure 22 2 Turn inner end cap clockwise viewed from shaft end about 2 or 3 turns 3 Turn outer end cap clockwise until the rotor is tight against the head and the Bearing Cross section shaft cannot be turned Inner 4 Make areference mark on bracket end opposite a notch on outer end cap Lipseal Endca 5 Back off the outer end cap required number of notches to obtain the required P end clearance Each notch is 0 0025 inches Consult the factory for your SS RYO specific end clearance requirement Tighten down the setscrews on the outer ee T A and inner end caps p S NS Bearing Locknut Lockwasher Bearing Spacer 10 PRESSURE RELIEF VALVE INSTRUCTIONS DISASSEMBLY Mark valve and head before disassembly to insure proper reassembly 1 2 3 4 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 a ways point towards suction side of pump If pump rotation is reversed remove the relief valve and turn end for end Refer to Figures 2 3 page 2 PRESSURE ADJUSTME
19. ugh a port opening between rotor teeth to keep shaft from turning Bend up the tab of lock washer which is engaging the lock nut and with a lock nut wrench remove the lock nut and lock washer from the shaft Remove the wood or brass from the rotor Remove the packing gland fastener and pull the gland out of the stuffing box Tap the shaft forward with a soft headed hammer and pull it out of the bracket and bushing assembly being careful not to damage the bracket bushing Remove the packing gland through the side of the bracket 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 pump on the bearing end of the bracket and press the bushing out through the packing area This will remove all of the packing with the bushing Remove the inner end cap with lip seal To remove the bearing from the bracket Tap the bearing forward with a soft headed hammer Clean all parts thoroughly and examine for wear and damage Check lip seals ball bearing bushings and idler pin and replace if necessary Check all other parts for nicks burrs excessive wear and replace if necessary 10 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 ra
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