- 1 -

MAINTENANCE INSTRUCTIONS

FOR GT PUMP RANGE

Standard Models

Quality Assured to ISO 9001 and BS5750 since 1985 for the Design, Manufacture and Repair of SEALLESS Pumps and Drives

© HMD/KONTRO SEALLESS PUMPS 2007 Ref. GTMI0107 Issue 2.1

- 2 -

- 3 -

European Union Machinery Directive (CE Mark System)

(where applicable) This document incorporates information relevant to the Machinery Directive 98/37/EC. It should be read prior to the use of any of our equipment. Individual maintenance manuals which also conform to the EU Directive should be read when dealing with specific models.

Disclaimer HMD / Kontro SEALLESS Pumps manufactures sealless pumps to exacting International Quality Management System Standards (ISO 9001) as certified and audited by Lloyd's Register Quality Assurance Limited. Genuine parts and accessories have been specifically designed and tested for use with these products to ensure continued product quality and performance. As HMD / Kontro SEALLESS Pumps cannot test all parts and accessories sourced from other vendors, incorrect design and/or fabrication of such parts and accessories may adversely affect the performance and safety features of these products. Failure to properly select, install or use authorised HMD / Kontro parts and accessories is considered misuse and damage or failure caused by misuse is not covered by HMD / Kontro's warranty. Additionally, modification of HMD / Kontro products or removal of original components may impair the safety of these products and their effective operation.

Copyright All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior permission of HMD / Kontro SEALLESS Pumps.

Safety The following safety precautions are to be taken in addition to safety procedures laid down by your company and do not supersede, change or absolve you from your statutory duties under government legislation. Our recommendations are based on our proven experience.

A pump that is not installed, operated or maintained in accordance with HMD/Kontro’s recommendations may present a hazard.

Attention must be given to the safe handling of all items. This applies to both installation and maintenance. Where pumps, pump units or components weigh in excess of 20Kg (44lb) it is recommended that suitable lifting equipment should be used in the correct manner to ensure that personal injury or damage to pump components does not occur. Note that lifting eyes fitted to individual pieces such as pump and motor are designed to lift only this part and not the complete assembly.

HMD / Kontro pumps contain high power magnets which may, in some circumstances, affect the operation of certain types of medical implants such as pacemakers. Wearers of these implants should take extreme caution when in proximity to an HMD / Kontro Sealless Pump. The assembled pump presents no known problems, however certain internal components need to be treated with caution. Do not wear a wristwatch when handling Inner or Outer Magnet Rings.

Before disassembling a pump all relevant and appropriate safety precautions must be taken. SEEK ADVICE FROM YOUR SAFETY REPRESENTATIVE OR THE MANUFACTURER IF YOU HAVE ANY DOUBTS.

Should the pumps have been used to pump toxic or hazardous products ensure compliance with COSHH and/or applicable Health and Safety legislation.

- 4 -

All pumps returned to HMD / Kontro for factory servicing must have a decontamination certificate and the appropriate Health and Safety data sheets.

After the pump has come to a complete stop, isolate the pump by shutting off all valves controlling flow to and from the pump, and any other measures required.

Always isolate the pump electrically before dismantling. Ensure that the electrical switchgear cannot be operated during any work being carried out on the pump. Ensure applicable lock-out/tag-out procedures are applied.

Care should be taken in assembling magnetic components due to their attraction with ferrous materials. Also particular care should be exercised when inserting or withdrawing the Inner Magnet Ring into or out of the Containment Shell contained within the Coupling Housing, due to the axial pull of the Outer Magnet Ring.

Always wear adequate protective clothing and eye protection when dismantling pumps. This includes all processes involving the use of compressed air and power tools, such as cleaning, grinding etc, and at all times during the assembly and disassembly of bearing components.

Introduction

This document details maintenance procedures to be followed in servicing GT Pumps, as detailed below: - The GT range is a magnetically driven centrifugal pump family with end suction and top discharge nozzles. The GT range is available in, but not limited to the following standards (where applicable): - GTA (ANSI / Imperial) HMD/KONTRO Standard

GTI (ISO / Metric) HMD/KONTRO Standard The GTA and GTI pumps are close-coupled designs. For HMD / Kontro guidance and recommendations covering pump foundation and commissioning, refer to the separate Installation & Operating Instructions. For further assistance call your nearest HMD/Kontro representative stating the pump serial number, or contact HMD/Kontro direct on:

Telephone: 01323 452000 (UK) +44 (1323) 452000 (Int) Facsimile: 01323 503369 (UK) +44 (1323) 503369 (Int) email: pumps@hmdpumps.com web: www.hmdkontro.com

GTMI0107 Iss 2

- 5 -

Contents Page number

Section 1 Tools Required 6

Section 2 Equivalent Terms and Units 7

Section 3 Clearances and End Floats 7

Section 4 Quick Reference Torque Settings 8

Section 5 Disassembly Instructions 9 - 16

Section 6 Replacement of Bush, Thrust Washers, and Sleeve 17 - 21

Section 7 Neck Ring Replacement 23

Section 8 Assembly Instructions 25 - 32

This Maintenance Manual must be read in conjunction with the Cross Sectional drawing and Parts List, both contained in the Data Package supplied.

This symbol within the following sections signifies a helpful hint that will assist the user in maintaining the HMD/Kontro pump.

This symbol within the following sections signifies information which must be followed to avoid personal injury.

GTMI0107 Iss 2

- 6 -

Section 1: Tools Required Note: AF means Across Flats

GTI GTA

Spanner (combination) 19mm AF x 2 3/4" AF x 2

Hexagon Key 5mm AF 3/16" AF

6mm AF 3/8" AF

10mm AF 6mm AF

Hexagon Key Socket 3mm AF long series 1/8" AF long series

5mm AF long series 3/16" AF long series

10mm AF 3/8" AF

10mm AF

Socket 19mm AF 3/4" AF

15/16" AF 15/16" AF

Torque Wrenches Norbar model SLO (or equivalent) Attachments (for above torque wrench): - Britool D1UBA, 1USB5M, and 1USB187 (or equivalent) General purpose 0 - 85Nm (0 – 63 lbf-ft)

General tools required

Small adjustable spanner Ratchet Extension bar Air wrench Soft Mallet

Lifting sling Levers or Pry bars x 2 Dial Test Indicator Soft drift e.g. made from wood (preferably ash) Medium size flat tip screwdriver x 2

Specialised tools

HMD impeller locking tools available: - GT15 (1 x 1 x 5 / 25-25-125) fixture number J1225E GT18 (1 x 1 x 6 / 25-25-160) fixture number J1225F GT19 (2 x 1.5 x 5 / 50-40-125) fixture number J1225D

Tools and equipment needed for replacing Bush: - One weight 55mm (2.1") diameter x 60mm (2.4") thick, preferably stainless steel Industrial oven to heat silicon Bush and weight to 100°C (212°F) Second industrial oven capable of 500°C (932°F), or industrial gas ring, or induction heater Temperature touch probe Heat resistant gloves, overalls, and safety glasses or facemask Tongs

GTMI0107 Iss 2

- 7 -

Section 2: Equivalent Terms and Units To assist in global understanding the following equivalent terminology is used: -

Used in this manual Also known as

Alignment Pad Support Gasket

Bush Radial Bearing or Journal Bearing

Close Coupled Frame Mounted

Containment Shell Shroud

Gasket Joint

Neck Ring Wear Ring

Spanner Wrench

Both Metric and equivalent US units are shown in this manual where appropriate. Conversion factors between units are: -

°C to °F multiply by 1.8 & add 32

mm to inches divide by 25.4

Nm to lbf-ft divide by 1.356

mls to US. Floz divide by 29.6

Section 3: Clearances and End-float Note N/A means Not Applicable

Component Diametrical Clearance Max/Min Wear Limits Recommended for

Replacement

(mm) (Inch) (mm) (Inch)

GT15 Front Neck Ring (41.01) 2.21 / 2.06 0.087 / 0.081 2.8 0.11

GT18 Front Neck Ring (41.01) 2.16 / 2.03 0.085 / 0.080 2.8 0.11

GT19 Front Neck Ring (41.01) 2.21 / 2.06 0.087 / 0.081 2.8 0.11

Bump Ring (43.44) to Outer Magnet Ring (51.51) 0.84 / 0.66 0.033 / 0.026 1.17 0.046

Outer Magnet Ring (51.51) to Containment Shell (20.20) 2.06 / 1.35 0.081 / 0.053 N/A N/A

Pump Shaft Assembly Inner Magnet Ring (02.02) to Containment Shell (20.20)

1.83 / 1.57 0.072 / 0.062 N/A N/A

Pump Shaft Sleeve (02.86) to Bush (09.10)

0.15 / 0.13 0.006 / 0.005 0.20 0.008

End-float (axial movement) of Pump Shaft Assembly (02.02) including Impeller (06.06)

0.56 / 0.20 0.022 / 0.008 2.5 0.098

The above table is for guidance only – if in doubt contact HMD/Kontro Pumps Ltd

or local representative

GTMI0107 Iss 2

- 8 -

Section 4: Quick Reference Torque Settings (Torque settings also contained in main manual)

REF

(Reference Number)

Description

Torque Setting

Nm lbf-ft

45.S11 Motor Retention Screws or Nuts 3/8” UNC or M10 30 22

45.S11 Motor Retention Screws or Nuts 1/2” UNC or M12 50 37

41.50 BSP Casing Drain Plug (optional) 25 18

41.N11 Casing Retention Nuts 85 63

20.S41 Bush Holder Retention Screws 16 12

02.03 Impeller Retention Screw 50 37

Note that Outer Magnet Ring (51.51) Retention Screws 51.S51 and 51.S61 do not have a torque setting due to deep recesses Screws are located in, and are therefore fully tightened by hand using long series hexagon key sockets. See Section 8.01 for details. Motor Adaptor Retention Screws (45.S41) cannot be accessed with a torque wrench; therefore fully hand-tighten. See Section 8.03 for details. It is not normally required that Motor Adaptor and Motor are separated; but if this is the case the above torque settings are given for both 3/8” and 1/2” UNC sizes (45.S11).

GTMI0107 Iss 2

- 9 -

SECTION 5

Disassembly of Pump

Before working on Pump ensure it is drained and decontaminated.

When disassembling the Pump, it is recommended that each set of fasteners be individually bagged. Tie a tag to each bag with the fastener Reference number (REF) written on the tag. Reference numbers are taken from the Cross Sectional Drawing and Parts List, and are contained in brackets ( ) in this manual. This will aid rebuilding, particularly where fasteners for different components are of similar size.

Work should be carried out in a clean area where possible. Bolt or clamp Coupling Housing (43.43) to workbench or other solid surface.

5.01 After following decontamination procedure, if Casing

(41.41) is fitted with Drain Plug (41.50 - arrowed), remove and drain product or flushing liquid from pump into suitable container. If BSP Drain Plug is fitted, use 15/16" AF socket and ratchet.

5.02 BSP Drain Plug – fit new Gasket (41.17A) to Drain Plug,

refit to Casing and torque to 25Nm (18 lbf-ft). NPT Drain Plug (41.50) – wrap fresh PTFE tape around thread, refit to Casing and fully tighten by hand using suitably sized socket.

GTMI0107 Iss 2

- 10 -

5.03 If Containment Shell (20.20) Temperature Sensor Probe

(43.TC) is fitted, ensure it is removed prior to disassembly of pump to avoid damage when Containment Shell is withdrawn. Undo top nut (arrowed) using small adjustable spanner and withdraw Probe.

5.04 If Thermal Ribbon RTD Temperature Sensor is fitted to

Containment Shell (20.20), Lock Nut on outside of Ribbon RTD Plug (43.50A) must be removed to enable socket connector to be pushed through as Containment Shell is withdrawn. Failure to do this will risk breaking Sensor tail. Refit Sensor dust cap (if available), then remove Lock Nut using 3/4” AF spanner.

5.05 Push Thermal Ribbon RTD connector through Ribbon

RTD Plug (43.50A).

5.06 Push connector all the way into pump Coupling Housing

(43.43).

GTMI0107 Iss 2

- 11 -

5.07 Early design pump - remove Casing Retention Bolts,

Nuts, and Washers (41.B11, 41.N11, 41.W11). Later design pump – remove Casing Retention Studs, Nuts and Washers (41.48, 41.N11 and 41.W11). Use either 19mm or 3/4" AF spanners.

5.08 Remove Casing (41.41) and Gasket (20.17). Dispose of

Gasket.

Gasket can sometimes still be attached to its location in Casing (41.41).

5.09 Remove Containment Shell Assembly (20.20), which

includes Impeller (06.06), Bush Holder (09.09), and Containment Shell (20.20) itself, from Coupling Housing (43.43). Groove on outside diameter of Containment Shell flange can be used to prise it from Coupling Housing if required (as shown).

Note that Containment Shell (20.20) is only held in Coupling Housing (43.43) by attraction of magnetic coupling. It is possible that Containment Shell may remain in Casing (41.41) when Casing is removed.

5.10 Care should be taken, as there will be resistance from magnetic coupling. Ensure weight of Containment Shell Assembly is supported whilst withdrawing from Coupling Housing to prevent damage to Containment Shell tube.

GTMI0107 Iss 2

- 12 -

5.11 If applicable, refit Thermal Ribbon RTD Lock Nut to

connector. This will prevent it becoming lost. Also, if green O-Ring is not attached to connector, it can usually be found inside Ribbon RTD Plug (43.50A) in Coupling Housing. If so, refit to connector as shown to prevent it falling down inside Coupling Housing.

5.12 Remove Impeller Retention Screw (02.03) using one of

the following methods to prevent Impeller (06.06) rotating whilst undoing Screw. Note that Screw is normal Right Hand thread.

Method ‘A’: - Insert locking bar between Impeller covers and undo Retention Screw using 10mm AF hexagon key socket and extension bar.

Method ‘B’: - Use air wrench if available (with 10mm AF hexagon key socket).

Method ‘C’: - Fit HMD Impeller Clamp tool to Impeller neck-ring and undo Retention Screw using 10mm AF hexagon key socket.

GTMI0107 Iss 2

- 13 -

5.13 Ensure hole (arrowed) through centre of Impeller Retention Screw (02.03) is clear of sludge or solidified product.

5.14 Remove Impeller (06.06). Care should be taken to

ensure Front Thrust Washer (07.07) located in back of Impeller does not fall out.

5.15 Remove Front Thrust Washer (07.07) from location

groove in back of Impeller. For full removal instructions see Section 6.09.

5.16 Remove Bush Holder Retention Screws (20.S41) using

5mm or 3/16" AF hexagon key depending on whether metric or imperial fasteners are fitted.

GTMI0107 Iss 2

- 14 -

5.17 Refit Impeller Retention Screw (02.03) and pull Pump

Shaft Assembly (02.02) along with Bush Holder (09.09) from Containment Shell (20.20).

5.18 If Bush Holder is stuck in Containment Shell due to solidified product, use either 6mm or 1/4" UNC forcing screws (not supplied) in holes provided in Bush Holder flange (both metric and imperial holes supplied). Forcing screws need to be minimum thread length of 12mm (1/2").

Be aware that strong magnets (Inner Magnet Ring) are fitted to main body of Pump Shaft Assembly. 5.19 Remove Bush Holder (09.09) from Pump Shaft Assembly

(02.02).

5.20 Ensure Bush Holder drain hole (arrowed) is clear of sludge or solidified product.

GTMI0107 Iss 2

- 15 -

5.21 Ensure bore of Pump Shaft Assembly and hole through

Shaft are clear of sludge or solidified product.

5.22 Disassembly of the liquid end is now complete.

It is advisable to support Motor using suitable lifting equipment. 5.23 Remove Motor Adaptor Retention Screws (45.S41) using

either 10mm or 3/8” AF hexagon key depending on whether metric or imperial Motor Adaptor is fitted.

5.24 Remove Motor (99.99) together with Motor Adaptor

(45.45) from Coupling Housing (43.43). If tight in its location, loosen carefully by tapping with soft mallet.

GTMI0107 Iss 2

- 16 -

5.25 Undo the two OMR Retention Screws (51.S51 and

51.S61) using either 3mm and 5mm, or 1/8" and 3/16" AF long reach hexagon keys or hexagon key sockets.

5.26 Remove Outer Magnet Ring (51.51) from Motor shaft

using two suitable levers. Care must be taken not to damage face of Motor Adaptor (45.45).

Ideally, due to its weight, a second person should be employed to hold Outer Magnet Ring as it comes loose.

5.27 If Coupling Housing Bump Ring (43.44) has been

damaged, remove from Coupling Housing (43.43) by drifting out from rear. Fit new Bump Ring using a soft drift to prevent damage to Bump Ring itself, which is made of phosphor bronze material. A suitable drift would be a wooden shaft made of ash.

GTMI0107 Iss 2

- 17 -

SECTION 6 Replacement of Bush, Thrust Washers, and Sleeve

If visibly worn or damaged it is strongly recommended that all bearings are renewed before re-assembling pump.

Read Instructions 6.01 to 6.08 carefully before proceeding with Bush replacement.

Guard against combustion of product residue on components. Whilst silicon carbide has excellent wear resistance, it is brittle and care must be taken in handling this material. Wear eye protection to guard against fracturing of silicon carbide bearings. Wear suitable protective clothing and heat resistant gloves while handling hot components. 6.01 Support Bush Holder (09.09) on two metal blocks as

shown. Ensure Bush Holder is level. Heat Bush Holder (09.09) in industrial oven or on industrial gas ring to applicable temperatures shown below and Bush (09.10) should fall out. If using an industrial gas ring, check Bush Holder frequently with a temperature touch probe.

Heat Bush Holder to following minimum temperatures: - 316SS holder with silicon carbide bush @ 250°C (482°F) Alloy 20 holder with silicon carbide bush @ 250°C (482°F) Alloy C holder with silicon carbide bush @ 305°C (581°F) Alloy 255 holder with silicon carbide bush @ 360°C (680°F) 316SS holder with carbon bush @ 420°C (788°F)

Allow Bush Holder to cool, then ensure Bush location in Bush Holder is clean and free of damage before proceeding. 6.02 Pre-heat replacement silicon carbide Bush (09.10) in

separate oven, and hold at 100°C (212°F) along with weight for a minimum period of 60 minutes. Note that carbon bushes are not pre-heated.

It is advisable to stand Bush with lubrication grooves in correct position for fitting in Bush Holder i.e. one of the lubrication grooves at the 3 o’clock position as shown (arrowed).

GTMI0107 Iss 2

- 18 -

6.03 Gas ring heating method: - Place Bush Holder on gas ring, flange downward. Place steel wrap

around Bush Holder. Cover top of wrap with a steel plate. This will ensure even heating of Bush Holder. Use temperature touch probe to monitor temperature of Bush Holder every 5 minutes by opening and closing steel wrap just enough to access Bush Holder. This will ensure minimal loss of heat. Bush Holder must reach relevant temperatures as per instructions in Section 6.01.

6.04 Induction heater heating method: - follow manufacturers instructions. 6.05 Oven heating method: - Place Bush Holder in second oven, flange downward. Set oven thermostat

to temperature required (see 6.01). Once oven reaches required temperature use temperature touch probe to monitor Bush Holder every 10 minutes. Increase oven temperature until required temperature of Bush Holder is obtained.

6.06 The following fitting operation must be carried out as quickly as possible to ensure Bush does not become stuck halfway into its location as Bush Holder cools down.

6.07 Remove Bush Holder from heat using metal tongs. With

flange downward, and 3mm drain hole (just above retention screw hole) in 6 o’clock position (arrow ‘A’), remove Bush (09.10) from oven and fit into Bush Holder with groove in 3 o’clock position (arrow ‘B’). Ensure Bush sits on Bush Holder bore location shoulder. Bush should drop easily into Bush Holder.

6.08 Remove pre-heated weight from oven and gently place

on Bush. Allow assembly to cool in draught free atmosphere.

‘A’

‘B’

GTMI0107 Iss 2

- 19 -

6.09 Remove Front Thrust Washer (07.07) from location

groove in back of Impeller. If difficult to remove, use compressed air or decontamination bath to loosen solidified product. In extreme cases it may have to be broken into pieces with hammer and dot punch.

Wear correct protective clothing, including overalls, gloves, safety glasses or face shield.

6.10 Remove Back Thrust Washer (08.08) from its location in

Pump Shaft Assembly (02.02). Again, if difficult to remove due to solidified product, refer to Section 6.09.

6.11 Carefully grip Pump Shaft Assembly in bench vice soft

jaws. Ensure solid metal ring (arrow ‘A’) at front of Inner Magnet Ring is gripped in vice to prevent damage to thin metal sheath (arrow ‘B’).

6.12 Remove Pump Shaft Sleeve (02.86) from Shaft.

Some force maybe required. Use a pulling and twisting action.

Wear protective gloves.

‘A’

‘B’

GTMI0107 Iss 2

- 20 -

6.13 If Pump Shaft Sleeve proves too difficult to remove by hand, it is possible to lever it off, but this risks damaging Sleeve, which would then have to be renewed.

Eye protection must be worn in case silicon carbide fractures.

6.14 In extreme circumstances it maybe necessary to break

Sleeve to remove it using hammer and dot punch. Any damage caused to Shaft using this method must be repaired prior to proceeding.

Eye protection and gloves must be worn.

6.15 Remove and discard O-Rings (02.OR1).

6.16 Remove and discard Alignment Pad (08.39).

GTMI0107 Iss 2

- 21 -

6.17 Fit new Alignment Pad (08.39) to Pump Shaft Assembly

(02.02).

Ensure cut-out (arrowed) in Alignment Pad aligns with Thrust Washer Location Pin (02.49C).

6.18 Fit two new O-Rings (02.OR1) into grooves in Pump

Shaft.

6.19 Fit new Sleeve (02.86) over O-Rings and push fully

down. Note that a firm rotating / pushing action will be needed to force Sleeve over O-Rings.

6.20 Fit new Back Thrust Washer (08.08) ensuring cut-out in

Thrust Washer aligns with Location Pin (02.49C) and lubrication grooves (arrowed) are uppermost

GTMI0107 Iss 2

- 22 -

GTMI0107 Iss 2

- 23 -

SECTION 7

Neck Ring Replacement

7.01 If Casing Neck Ring (41.01) is visibly worn or damaged, remove from Casing (41.41). Neck Rings are retained by an interference fit and can be removed from their locations by using a suitable puller or pry bar. Alternate pry bar from left to right hand side, and top to bottom. This will ensure Neck Ring pulls out evenly.

Note that Neck Ring is sometimes pinned. When Neck Ring is removed discard old Pins. New holes will have to be drilled for Pins equally spaced at the join of the Neck Ring and Casing body. Holes should be drilled 3mm diameter by 12mm deep. Fit new Pins (41.49D) using pin punch.

7.02 Before fitting new Neck Ring (41.01) ensure Casing location is within the dimensional limits shown in table below: -

Pump Size ANSI / Imperial ISO / Metric Neck Ring Location

Bore (Imperial) Neck Ring Location

Bore (Metric)

GT15 1 x 1 x 5 25 x 25 x 125 2.678 / 2.677 68.030 / 68.000

GT18 1 x 1 x 6 25 x 25 x 160 2.759 / 2.758 70.080 / 70.050

GT19 2 x 1.5 x 5 50 x 40 x 125 3.5455 / 3.5445 90.060 / 90.030

7.03 Neck Rings (41.01) should be fitted using a soft drift or soft mallet until it seats against its shoulder.

Note that leading edge of Neck Ring has a 15° chamfer to aid fitting.

GTMI0107 Iss 2

- 24 -

GTMI0107 Iss 2

- 25 -

SECTION 8

ASSEMBLY INSTRUCTIONS

To prevent leaks, ensure all Forcing Screws used to disassemble Pump are either removed or withdrawn to their original position. Ensure all Pump Components are clean and in "as new" condition. The pump assembly should be carried out in a clean dry area. Bolt or clamp Coupling Housing to workbench or other solid surface.

8.01 Fit Outer Magnet Ring (51.51) to Motor Shaft. Outer Magnet Ring is manufactured to a tight sliding fit and may require drifting gently onto Shaft. DO NOT USE EXCESSIVE FORCE AS THIS MAY DAMAGE BALL RACES IN MOTOR! See Section 8.02 for correct position of Outer Magnet Ring on Motor Shaft. Place a drop of Loctite 242 Threadlocker on each of the OMR Retention Screws (51.S51 and 51.S61). Fully hand tighten OMR Retention Screws using 3mm and 5mm, or 1/8" and 3/16" AF long series hexagon keys or hexagon key sockets.

8.02 Note that Outer Magnet Ring (OMR) flange must be fitted flush with end of Motor Shaft. OMR must not come into contact with end of Containment Shell (20.20).

Motor Shaft

Ensure OMR inner flange face sits flush

with end of Motor Shaft

GTMI0107 Iss 2

- 26 -

It is advisable to support Motor using suitable lifting equipment.

8.03 Fit Motor with attached Outer Magnet Ring into Coupling Housing (43.43). Fit Motor Adaptor Retention Screws (45.S41) or Nuts (45.N11). Tighten Screws or Nuts evenly. Where accessible, torque M10 or 3/8” fasteners to 30Nm (22lbf-ft). Torque M12 or 1/2” fasteners to 50Nm (37lbf-ft). Where torque wrench cannot be fitted, fully hand-tighten fasteners. Ensure Motor terminal box is aligned correctly with Coupling Housing.

8.04 Check run-out of Outer Magnet Ring (51.51) to Coupling Housing face by fitting Dial Test Indicator with ferrous metal base to bore of Outer Magnet Ring. Rotate slowly through 360° checking run-out on face does not exceed 0.25mm (0.010").

8.05 Check run-out of Outer Magnet Ring (51.51) to Coupling Housing Containment Shell location spigot (arrowed). Rotate slowly through 360° avoiding Containment Shell Location Pin (43.49A). Check run-out on spigot does not exceed 0.25mm (0.010").

Note use of special 90° attachment on Dial Test Indicator to ensure accurate reading. After removing Dial Test Indicator, ensure bore of Outer Magnet Ring is clear of any ferrous particles that may have become stuck to magnets.

8.06 If run-out dimensions detailed in Sections 8.04 and 8.05 are exceeded, remove Outer Magnet Ring and Motor Adaptor (45.45) from Motor. Stand Electric Motor on its end with Drive Shaft uppermost. Fix a Dial Test Indicator to Motor Shaft. A standard DTI base can be clamped to Motor Shaft by: - 1. Screw eyebolt (‘A’) into end of Shaft. 2. Place a piece of metal plate (‘B’) on one side of eyebolt. 3. Use G-Clamp (‘C’) to secure DTI to other side of eyebolt. This will give a firm steady base for the DTI.

‘A’ ‘B’ ‘C’

GTMI0107 Iss 2

- 27 -

8.07 Check run-out of Motor drive shaft to Motor Flange spigot. Run-out must not exceed 0.10mm (0.004").

8.08 Note use of special 90° attachment for accurate run-out measurement of spigot (arrowed).

8.09 Check run-out of Motor drive shaft to Motor Flange face. Run-out must not exceed 0.10mm (0.004"). If Motor run-outs are within tolerance, fault may lie with Motor Adaptor Assembly (45.45). Either refit Motor Adaptor Assembly to Motor and repeat run-out checks on Motor Adaptor Assembly itself, or mount Motor Adaptor Assembly in centre lathe and check for run-out of faces and spigots.

Ensure surface of Inner Magnet Ring attached to Pump Shaft is clear of any ferrous particles that may have become stuck to magnets.

8.10 Insert Pump Shaft Assembly (02.02) into Containment Shell (20.20).

GTMI0107 Iss 2

- 28 -

8.11 Very carefully fit Bush Holder (09.09) over Pump Shaft and into Containment Shell location.

Extreme care must be taken not to damage silicon carbide Sleeve (02.86) and Bush (09.10). Align off-set Retention Screw holes. Containment Shell flange will normally be dual drilled with metric and imperial threaded holes (six holes in total) with one set of holes blanked off.

8.12 Fit Bush Holder Retention Screws (20.S41). Tighten evenly by hand using either 5mm or 3/16" AF hexagon key depending on whether metric or imperial fasteners are being used, then torque to 16Nm (12 lbf-ft).

Ensure surface of Containment Shell is clear of any ferrous particles that may have become attracted to Inner Magnet Ring within Containment Shell.

8.13 Note position of Containment Shell Location Pin (43.49A) fitted to Coupling Housing (43.43). Also note position of corresponding hole in back of Containment Shell flange prior to fitting Containment Shell (20.20).

It is advisable to mark position of Pin and corresponding hole in back of Containment Shell flange with indelible marker to aid correct alignment.

Beware of forceful magnetic attraction between Outer Magnet Ring and Inner Magnet Ring (fitted to Pump Shaft) when fitting Containment Shell assembly into Coupling Housing.

8.14 Fit Impeller Retention Screw to Pump Shaft. Grip Screw and support Containment Shell flange, then very carefully slide into Outer Magnet Ring within Coupling Housing, keeping fingers out of gap between Containment Shell flange and Coupling Housing. Align hole in back of Containment Shell flange with Location Pin and push fully home. Ensure flange is located on Pin by trying to move flange from side to side.

GTMI0107 Iss 2

- 29 -

8.15 If a Thermal Ribbon RTD Temperature Sensor is fitted to Containment Shell, ensure green coloured O-Ring is fitted to Sensor (remove lock-nut if fitted). As Containment Shell is slid into pump body, carefully feed leads attached to Sensor dust cap through Ribbon RTD Plug (43.50A).

Ensure tail of Sensor is not twisted.

8.16 It is advisable to tie a length of stiff wire to the dust cap or dust cap leads and feed this through Ribbon RTD Plug first. This will enable second person to guide Sensor through Plug, as first person fits Containment Shell Assembly.

8.17 Slide Lock Nut over dust cap leads and tighten Lock Nut using 3/4” AF spanner.

8.18 Fit new Front Thrust Washer (07.07) to Impeller (06.06) ensuring location groove is clean and free from burrs, dents etc.

GTMI0107 Iss 2

- 30 -

8.19 When re-fitting Impeller (06.06) ensure off-set hole (arrowed) is correctly aligned with off-set hole in Pump Shaft (02.02).

8.20 Fit Impeller to Pump Shaft and hand tighten Retention Screw (02.03) with 10mm AF hexagon key socket. Either fit Impeller locking tool as shown (see list of available special tools on page 6), and secure locking tool to Impeller with 6mm AF hexagon key, or lock Impeller by inserting locking bar between Impeller covers to prevent rotation as described in Section 5.12.

8.21 Torque Impeller Retention Screw (02.03) to 50Nm (37 lbf-ft) using 10mm AF hexagon key socket.

Extreme care must be taken when applying force to torque wrench (and counter-force to Impeller locking tool) to ensure Containment Shell (20.20) is fully located on Location Pin (43.49A) in Coupling Housing. This is to prevent whole assembly from either rotating and breaking Thermal Ribbon RTD Temperature Sensor (if fitted), or spinning assembly from Coupling Housing.

8.22 Place Dial Test Indicator against Impeller front cover and set to zero. Grasp front and rear Impeller covers between thumbs (on front cover) and fingers (behind rear cover). While pushing Containment Shell back into its location in Coupling Housing with back of fingers, ease Impeller back and forth with thumbs and fingers to give reading on Dial Test Indicator. This will ensure that Containment Shell is not pulled out of Coupling Housing. Total axial movement is called end-float. End-float should measure between 0.20mm and 0.56mm (0.008" and 0.022").

GTMI0107 Iss 2

- 31 -

8.23 Fit new Containment Shell Gasket (20.17).

8.24 Fit Casing (41.41) to Coupling Housing (43.43). Early design pump – secure using Casing Retention Bolts, Nuts, and Washers (41.B11, 41.N11, 41.W11). Later design pump – secure using Casing Retention Studs, Nuts and Washers (41.48, 41.N11 and 41.W11). Pull Casing evenly and fully onto Coupling Housing using either 19mm or 3/4” AF spanner, and then torque Nuts fully using torque wrench and either 19mm or 3/4" AF socket. See Section 8.25 for torque settings.

8.25 To ensure Containment Shell Gasket (20.17) is evenly compressed, tighten pairs of Nuts diametrically opposite each other following the pattern shown on the right. Torque Nuts in stages of 30Nm, 60Nm, and finally 85Nm (22 lbf-ft, 44 lbf-ft, 63 lbf-ft).

8.26 Refit Containment Shell (20.20) Temperature Sensor Probe (43.TC) if applicable. Tighten top nut (arrowed) using small adjustable spanner just sufficiently to affect a seal.

Do not over-tighten nut as this may damage probe.

GTMI0107 Iss 2

- 32 -

8.27 Pump is now complete.

GTMI0107 Iss 2

- 33 -

GTMI0107 Iss 2

- 34 -

Your Local Agent

Quality Assured since 1985 for the

Design, Manufacture and Repair of

Sealless Pumps and Drives

HMD Seal/less Pumps Ltd Hampden Park Industrial Estate,

Eastbourne, East Sussex, BN22 9AN, ENGLAND. Tel: +44 (0) 1323 452000 Fax: +44 (0) 1323 503369 e mail: pumps@hmdpumps.com

web: www.hmdkontro.com