Tonkaflo

PumpsAS Series

Installation, Operation

and Maintenance Manual

For AS8000, AS13500, AS2100, and AS40000 High Pressure Tonkaflo Centrifugal Pumps with

Type K-Bearing Frame

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

FOR SERIES AS8000, AS13500, AS21000, AND AS40000

HIGH PRESSURE TONKAFLO® CENTRIFUGAL PUMPS WITH TYPE K-BEARING FRAMES

TABLE OF CONTENTS

Page

1.0 INTRODUCTION 1

2.0 TONKAFLO SPECIFICATIONS 2

2.1 Capacities 22.2 Maximum Developed Boost Pressure 22.3 Maximum Recommended Operating Temperature 32.4 Pump Nomenclature Example 32.5 Standard Materials of Construction 32.6 Special Materials of Construction 32.7 Special Liquids 3

3.0 PUMP INSTALLATION 4

3.1 Inspection 43.2 Location 43.3 Foundation 43.4 Flexible Coupling Installation 43.5 Coupling Guard 53.6 Piping 53.7 By-Pass Piping For Multi-Stage Pumps 73.8 Suction Screen (Strainer) 73.9 Pump Piping Connections 73.10 Lubrication of Pump Bearings 8

3.10.1 Setting the Oil Level 93.10.2 Maintaining the Oil Level 10

4.0 PUMP OPERATION 11

4.1 Pump Priming 114.2 Pump Rotation 114.3 Initial Operation 12

Page

5.0 GENERAL TROUBLESHOOTING 13

5.1 Troubleshooting Chart 135.2 Bearing Frame Temperature 14

6.0 TONKAFLO PUMP FIELD MAINTENANCE 14

6.1 Mechanical Seal Leakage 146.2 Removal and Installation of Liquid End Assembly 14

6.2.1 Removal of Liquid End Assembly 146.2.2 Installation of Liquid End Assembly 15

6.3 Mechanical Seal Replacement 166.4 High Pressure Mechanical Seal Replacement 176.5 Bearing Frame Maintenance of K-Frame Tonkaflo Pumps 17

6.5.1 Disassembly of Pumps with Type K-Bearing Frames 176.5.2 Assembly of Pumps with Type K-Bearing Frames 19

6.6 Oil Seal Replacement 226.6.1 Replacement of Oil Seal #2, Figure 6.7 226.6.2 Replacement of Oil Seal #1, Figure 6.7 236.6.3 Replacement of Oil Chamber Bulkhead 23

6.7 Lubrication 246.7.1 Adding Oil 246.7.2 Changing Oil 24

7.0 TONKAFLO SERVICE POLICY - LIQUID END 25

8.0 TONKAFLO PUMP RETURN GOODS AUTHORIZATION(RGA) PROCEDURE 26

8.1 Out-of-Warranty Pump Failure 268.2 In-Warranty Pump Failure 268.3 Shipping Charges 27

8.3.1 In-Warranty 278.3.2 Out-of-Warranty When New Pump is Purchased 27

9.0 DIMENSIONAL DRAWING 28

10.0 REPLACEMENT PARTS 29

10.1 Cutaway Drawing 2910.2 Parts List, Standard Models 3010.3 Accessories for the All-Stainless Series Tonkaflo Pumps 31

Page

10.4 Recommended Spare Parts List for Standard Tonkaflo Pumpswith K-Bearing Frames 32

10.5 Complete Set of Bearing Frame Replacement Parts 3310.6 Bearing Frame Overhaul Tools 3310.7 Mechanical Seal Change-Out Tools 3410.8 Ordering Parts 34

11.0 WARRANTY 36

LIST OF FIGURESPage

Figure Title

3.1 Gap Between Flanges 43.2 Suction Lift Piping 63.3 Victaulic Type Coupling Assembly 83.4 Initial Cold Setting of Oil Level 106.5 Separation of Liquid End From Bearing Frame 156.6 Removal of Mechanical Seal 166.7 Bearing Frame Overhaul 186.8 Setting Bearing Frame Shaft End Play 209.9 Dimensions, Pump Only 28

10.10 Pump Cutaway Drawing 29

LIST OF TABLESPage

Figure Title

3.1 Typical Heavy-Duty Hydraulic Oil Types 9

1.0 INTRODUCTION

This manual contains information important to the installation, operation, and mainte-nance of your Tonkaflo multi-stage, stainless steel centrifugal pump. The Tonkaflo pumphas been designed for reliable service in many types of pumping applications. Properinstallation and normal maintenance will help insure extended pump life and preventcostly downtime. Before installing and operating your Tonkaflo pump, read theseinstructions carefully and keep the manual handy for future reference. Further informa-tion may be obtained by contacting your local Tonkaflo distributor or Osmonics, Inc.,5951 Clearwater Drive, Minnetonka, MN 55343-8995, USA, Phone: (952) 933-2277, Fax: (952) 933-0141.

This manual is not intended for repair or overhaul of the Tonkaflo pump liquid ends.Only the factory or those who have successfully completed the Factory Service Schooland have been certified are authorized to repair, service or overhaul Tonkaflo pump liq-uid ends.

Your new Tonkaflo multi-stage stainless steel constructed centrifugal pump is designedfor quiet, smooth running, and highly efficient operation. The materials of constructionmake Tonkaflo suitable for many chemical, corrosive, and pure water applications.

Tonkaflo pumps' unique modular design allows the user to choose the number of stageswhich most closely match the desired performance and, thereby, achieve the highestpumping efficiency. Unlike many other pump manufacturers, Tonkaflo will producepumps to fit your particular applications should a standard model pump not suit yourrequirements.

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2.0 TONKAFLO SPECIFICATIONS

The Tonkaflo pumps covered in this Installation, Operation and Maintenance Manual arethe higher capacity AS8000, AS13500, AS21000, and AS40000 Series pumps. These fourseries of pumps cover a flow range of 30 - 500 gpm (0.3 - 12.5 m3/h) at 3450 rpm (60Hz) with single unit pressures up to 500 psig (34.5 bar). See the table below. The capac-ity and discharge pressure can be increased by operating the pumps in parallel or series,respectively. There is no maximum limit on capacity when operating Tonkaflo pumps inparallel. When operating pumps in series, a maximum discharge pressure of 1000 psig(69 bar) may be achieved. With inlet pressures of 200 psig (13.8 bar) or greater, option-al high-pressure mechanical seals should be used.

2.1 Capacities

NOTE: There must be adequate flow at all times through the pump to prevent exces-sive heat buildup.

2.2 Maximum Developed Boost Pressure

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3500 rpm Max No. 2900 rpm Max No. Max60 Hz of Stages 50 Hz of Stages Efficiency

Stages Min-Max (60 Hz) Min-Max (50 Hz)

8000 30 - 106 gpm 27 25 - 86 gpm 39 66%(6.8 - 24.1 m3/h) (6 - 19 m3/h)

13500 60-150 gpm 18 50 - 130 gpm 25 62%(13.6 - 34.1 m3/h) (11 - 29 m3/h)

21000 100- 260 gpm 19 80-120 gpm 26 64%(22 .7 - 59 m3/h) (18-48 m3/h)

40000 250 - 525 gpm 12 200-425 gpm 15 78%(56.8 - 119.2 m3/h) (45.4-96.5 m3/h)

Stages Developed Pressure Stages Developed PressureSeries (60 Hz) (60 Hz, 3500 rpm) (50 Hz) (50 Hz, 2900 rpm)

8000 27 Up to 500 psig (34 bar) 39 Up to 500 psig (34 bar)

13500 18 Up to 380 psig (26 bar) 26 Up to 370 psig (25 bar)

21000 19 Up to 380 psig (26 bar) 26 Up to 400 psig (27 bar)

40000 12 Up to 420 psig (29 bar) 15 Up to 370 psig (26 bar)

2.3 Maximum Recommended Operating Temperature

The maximum recommended operating temperature range is 200°F (93°C) forthe standard stainless steel stages. For higher temperature applications, consultyour local Tonkaflo distributor or the factory for the available special materialsof construction.

Pumps have the maximum recommended temperature stated on the label on thepump case. The temperature stated is for the design flow and pressure.

2.4 Pump Nomenclature Example

2.5 Standard Materials of Construction

AS: Wetted castings are 316 stainless steel. The pump shaft and casing are type304 or 316 stainless steel. Impellers and diffusers are 304 stainless steel.The mechanical seal has a carbon rotating face and a ceramic stationary face.The secondary sealing element of the mechanical seal is ethylene propyleneEPDM. The standard mechanical seal is a Crane Type 21. The standard O-rings, shaft bearings, and impeller eye seals are EPDM. All AS40000 pumpsuse Poly Tetrafluoroethylene (PTFE) shaft bearings and impeller eye seals asstandard.

2.6 Special Materials of Construction

Special elastomers and metals are available. Contact your distributor or the fac-tory.

2.7 Special Liquids

Tonkaflo pumps can handle a variety of liquids. For liquids other than water,aqueous solutions at elevated temperatures, or chemical solutes, consult yourlocal Tonkaflo distributor or the factory for compatibility.

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Model AS8023KC

AS = All Stainless Steel

80 = Series 8000

23 = Number of Stages

K = Bearing Frame

C = Motor Adapter

3.0 PUMP INSTALLATION

3.1 Inspection

Your pump was inspected and tested at the factory prior to shipment to assuremeeting the requirements of your order. It is suggested the pump be checkedupon receipt for possible damage due to shipping. Any damage should be report-ed immediately to the carrier. The pump must always be drained before shippingif exposure to freezing temperatures is likely.

3.2 Location

Install the pump as close as possible to the source of the liquid being pumped. Ifthe liquid source is remote or located several feet away from the high-pressureprocess pumps, a transfer pump at the source will be needed to transfer the liq-uid to the high pressure pump. It is ideal for the pump to be fed from a reser-voir above the pump or from a supply line under positive pressure.

3.3 Foundation

The foundation for the motor and pump must be sufficiently rigid and substantialto prevent any significant vibration of the pump or deflection of the motor andpump shafts when operating the pump. The recommended foundation is of rein-forced concrete or a heavy steel skid.

The pump mounting is to be horizontal and the pump leveled within 1/16-inch/ft (4.5 mm/m) both in the axial and side-to-side directions. The pump case and flatboss on the bearing frame is the best reference for leveling.

3.4 Flexible Coupling Installation

If the pump has not been supplied as an assembled unit, install the coupling flangeon the motor shaft. Do not tighten set screws until after the pump and motorare assembled.

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Figure 3.1Gap Between Flanges

Coupling GapSize inch (mm)

6 7/8 (22.2)7 1 (25.4)8 1-1/8 (28.6)9 1-7/16 (36.5)

Install the flexible coupling sleeve onto the pump coupling flange and assemble thepump and motor. Adjust the gap between the coupling flanges to the valuesshown in Figure 3.2 within +1/16 - 0-inch (+1.5 - 0 mm).

3.5 Coupling Guard

Coupling guards are available as an option on Tonkaflo pumps. A coupling guardis recommended. Check your plant safety requirements.

3.6 Piping

The pump inlet housing has been designed for either upright, left, or right hori-zontal positioning. The pump is shipped with the inlet in the upright position. Forthe left or right position, remove the four (4) bolts holding the suction (inlet)housing to the bearing frame. Rotate the suction housing 90° and replace thefour (4) bolts. When in this position, a pipe plug in the top of the pump inlethousing can be removed to vent off any air, should “venting” be required forpump priming and start-up.

Suction (pump inlet) piping should be of ample size, installed in direct runs, andhave a minimum of bends to minimize pressure loss and help ensure sufficientsuction pressure. When possible, keep the suction piping short.

The suction (inlet) pipe size immediately ahead of the pump inlet should be suffi-ciently sized so that the pressure available at the pump suction (inlet) exceeds theNet Positive Suction Head (NPSHR). required by the pump. Generally, the suc-tion (inlet) piping should be as follows:

For most pump applications, it is recommended the pipe size selected result infrictional line loss of 3 psig/100 feet (0.21 bar/meter) or less for suction lines and10 psig/100 feet (0.69 bar/meter) or less for discharge lines. A larger pipe sizewill reduce the frictional line loss.

The pump inlet piping should be designed to avoid areas where air may betrapped and accumulated. These air pockets tend to disrupt pump priming andstart-up. To avoid air pockets, the suction piping should be kept free of highpoints. Suction pipe size changes just ahead of the pump should be tapered, andeccentric reducers should be used.

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8000, 13500 pumps 3-inch (7.6 cm)21000, 40400 boost pumps 4-inch (10.2 cm)40600 transfer pump 6-inch (15.2 cm)

The discharge piping should be sized to properly handle the maximum flow andpressure developed by the pump. Three-inch (76 mm) piping is recommendedfor the AS8000, AS13500, and AS21000 Series. For the AS40000 Series pumps,4-inch (102 mm) piping is recommended.

When the pump operates with a suction lift, the suction pipe should slopeupward to the pump from the source of supply (Figure 3.2). Provisions must bemade for priming the pump. To maintain pump prime, a foot valve can be usedwith an opening at least as large as the inlet piping. An alternate method wouldbe to use a shut-off valve on the discharge line and a vacuum pump to draw airout of the pump and suction line.

When pumping liquid from a tank, the suction line must be submerged enough soair is not drawn into the suction line from a vortex. Increasing the size of theinlet pipe to reduce the velocity will help to prevent the vortex from forming.

Hot liquids within the temperature range of the pump must have sufficient posi-tive head to prevent vaporization at the impeller inlet. Consult the factory oryour local Tonkaflo distributor for NPSH requirements of the pump for yourapplication.

The pump must never be throttled on the suction side.

After installation, test the suction line with water with a pressure of 20 - 100 psig (1.4 - 6.9 bar) to detect any leaks.

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Figure 3.2Suction Lift Piping

3.7 By-Pass Piping for Multi-Stage Pumps

Sufficient flow must be maintained through a multi-stage pump to prevent thepump from overheating. Low flow rates result in excessive energy accumulationand heat build-up in the pump. Minimum recommended flows are shown inSection 2.0.

A by-pass pipe, that is, a pipe from the discharge piping back to the source of liq-uid supply or suction line, may be needed for your installation to ensure that thepump operation is within the specified flow range. It is recommended that theconnection of a by-pass pipe to the suction line be at least 24-inches (61 cm) awayfrom the pump inlet.

3.8 Suction Screen (Strainer)

This is a precision multi-stage centrifugal pump with close tolerances to providemaximum efficiency.

It is good practice to install a 30-mesh or finer screen (available as an accessory)or a cartridge filter in the suction line to collect any foreign objects or larger par-ticles.

The pump must not be operated with restricted suction line (inlet flow).

Positive gauge pressure must be maintained at the pump inlet (downstream fromthe filter or screen). A clogged screen or filter will result in a greater pressuredrop. A two pressure alarm or shut-off switch located between the screen orfilter and the pump should always be used in conjunction with a suction linescreen or filter.

3.9 Pump Piping Connections

The standard model Tonkaflo All-Stainless Steel Series pumps have grooved endsto accept Victaulic type couplings, as shown in Figure 3.3. Couplings with a 1000psig (69 bar) working pressure rating are available as an accessory and include aBuna-N gasket (standard). Other gasket materials such as Viton* or ethylenepropylene are available. Consult the factory.

The coupling gasket should be thoroughly lubricated before installation. Siliconegrease is recommended. Petroleum grease is suitable for most gasket materials,but is not suitable with EPDM.

* Viton is a trademark of E.I. du Pont de Nemour and Company, Inc.

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3.10 Lubrication of Pump Bearings

The pump bearings are not lubricated at the factory.

The bearings are lubricated by maintaining a static oil level within the bearingframe. An oiler ring circulates the oil from the reservoir through the bearings.An oil sight gauge, with “FULL” and “ADD” lines, is provided on the bearingframe so the oil level may be viewed and maintained.

One quart (0.9 L) of oil is provided with each new Tonkaflo oil lubrication pump.Two quarts (1.9 L) are provided for KT-Bearing frame pumps.

A heavy duty premium hydraulic lubricating oil (anti-wear, non-detergent, rust,oxidation, and foam inhibited) should be used, such as those listed in Table 3.1.

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Figure 3.3Victaulic Type Coupling Assembly

Table 3.1Typical Heavy Duty Hydraulic Oil Types

3.10.1 Setting the Oil Level

The bearing frame oil reservoir capacity is approximately one quart (oneliter). Remove the vent located on the top of the bearing frame and pourin the oil. A nozzle is provided with the oil to aid in pouring the oil.Continue adding oil until the “FULL” level line is reached on the sightgauge (Figure 3.4).

DO NOT OVERFILL THE BEARING FRAME. Setting the initial cold oillevel higher than specified will result in higher oil operating temperaturesand reduced oil life.

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Manufacturer Description

Tonkaflo Pumps Anti-wear Hydraulic Oil1 Quart P/N 112069312-Quart Case P/N 1120682

Shell Tellus Anti-wear Hydraulic OilCode 65214

Lubriplate HO-2 or HO-68 Anti-wear Hydraulic Oil (silicone-free)

The oil will run between 130 - 220°F (54 - 104°C). Normally, operating conditions willrequire a heavy-duty oil with a viscosity of 465 SSU at 100°F (38°C) (ISO-Vg grade 100).

3.10.2 Maintaining the Oil Level

Maintain the oil level between the “FULL” and “AND” marks on the sightgauge (Figure 3.4). The bearing frame should run with the oil level at the“FULL” mark. Approximately 8 ounces (0.24 L) of oil is required to raisethe oil level from the “ADD” to the “FULL” level lines.

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Figure 3.4Initial Cold Setting of Oil Level

4.0 PUMP OPERATION

4.1 Pump Priming

THE INLET PIPING AND PUMP MUST BE FILLED WITH LIQUID (i.e., PRIMED)BEFORE START-UP. If the pump is below the liquid source or connected to apositive pressure source, the pump may be primed from that source.

If the pump is above the liquid source, fill the pump and supply line with liquidfrom an external source.

The pump should be shut-off immediately if prime is lost to avoid overheating andpossible damage to the internals of the liquid end.

The pump should not run with a closed discharge for more than 3 minutes. Theliquid can heat up very quickly and exceed the maximum operating temperature,causing irreversible damage to the wetted internal parts of the liquid end.

CAUTION: NEVER RUN PUMP DRY.

In order to adequately protect the pump from running dry, it is suggested thatcontrols to protect the pump be used. These controls include: pressure switch-es, flow switches, and temperature switches.

4.2 Pump Rotation

When initially connecting to the power source, be certain that the motor wiringand available line voltage are the same. Connect the wires as shown on themotor wiring diagram located on the inside of the motor junction box cover oron the nameplate label.

CAUTION: If a three-phase (3-phase) motor is wired incorrectly, it will causethe pump shaft to rotate in the wrong direction. This will resultin low pressure (about 1/4 to 1/2 of normal) and low flow (about1/2 of normal).

A motor starter is required for all 3-phase motors.

BEFORE STARTING 3-PHASE MOTORS:

1. Prime pump before applying power to avoid damage to pump.

2. Apply power for ONE SECOND to check direction of motor shaft rotation.The motor shaft should turn in a clockwise direction as viewed from themotor end.

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The direction of rotation for 3-phase motors may be reversed by inter-changing any two leads.

4.3 Initial Operation

With the oil reservoir filled, oil level set, pump primed, and pump rotationchecked, your pump is ready to operate.

Upon start-up, check to see that the correct boost pressure level is obtained atdesign flow.

If prime was not achieved, re-prime as necessary.

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5.0 GENERAL TROUBLESHOOTING

5.1 Troubleshooting Chart

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LOW FLOW MOTOR RUNS HOT OR STOPS

1. Restrictions in inlet or discharge 1. Motor wire improperly2. Foot valve operating improperly 2 Bad connection3. Air leak in inlet piping 3. Motor exceeding rated amp draw4. Air leak in mechanical seal 4. Excessive ambient temperature5. Suction lift too high 5. Heater size too small in motor starter6 Reverse rotation to pump shaft 6. Binding rotation in the pump shaft7. Pump not primed adequately 7. Bearing not lubricated adequately8. Inlet strainer/filter plugged 8. Specific gravity or viscosity of liquid higher

than design conditions

MOTOR DOES NOT RUN LOW PRESSURE

1. Blown fuse or tripped circuit 1. Pump not primed adequatelybreaker or overload heater 2. Air leak in inlet piping

2. Motor too hot - allow to cool 3. Excessive flow3. Motor voltage connection and line 4. Clogged suction line filter or screen

voltage different 5. Reverse rotation of pump shaft4. Bad connection 6. Foot valve operating improperly5. Motor wired improperly

PUMP VIBRATION PUMP LEAKING

1. Bent pump shaft 1. Mechanical seal needs replacing2. Improper mounting 2. O-rings in pump casing damaged3. Starved suction 3. Oil seals need replacing4. Worn bearings 4. Piping not properly sealed5. Motor is out of balance

5.2 Bearing Frame Temperature

The operating temperature of the oil lubricated K-Bearing frames utilized on highpressure Tonkaflo pumps will vary depending on the boost pressure of the pump.As a general rule, K-Bearing frames will operate within a temperature range of130 - 220°F (54 - 105°C). During operation, the bearing frame will feel hot tothe touch. A new bearing frame will run cooler after 24 hours of operation.Bearing frame temperatures will typically decrease further after a few weeks asthe bearings break in. Pumps operating on 50 Hz power (2875 rpm) will oper-ate cooler.

6.0 TONKAFLO PUMP FIELD MAINTENANCE

6.1 Mechanical Seal Leakage

If liquid is leaking from the hole on the bottom or the holes on either side of thebearing frame near the inlet, the mechanical seal may need to be replaced. Withnew pumps, pumps with new mechanical seals, or pumps which have been dor-mant for long periods, the seal faces may not be completely seated and a slightleakage will occur. If this leakage continues for more than 60 seconds, removedischarge piping and tap pump shaft using a wooden dowel to seat the seal. Becareful not to damage the pump shaft.

WARNING: POWER MUST BE DISCONNECTED BEFORE MAIN-TENANCE.

6.2 Removal and Installation of Liquid End Assembly

6.2.1 Removal of Liquid End Assembly

Removal of the liquid end assembly is required for replacement of themechanical seal or for maintenance work on the pump bearing frame asdescribed in Sections 6.3 - 6.6. The liquid end may be removed from thebearing frame without removing the bearing frame from the bedplate orother mounting.

STEPS:

1. Remove the four (4) 3/8-inch bolts and lock washers connecting theliquid end assembly to the bearing frame as shown in Figure 6.5.

2. Insert a 3/16-inch Allen (hex) wrench in one of the access holes oneither side of the bearing frame toward the liquid end. Refer to Figure6.5 for more detail. Rotate the pump shaft until the Allen wrench slipsinto the set screw. Rotate the shaft by rotating the flexible coupling.

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3. Loosen the clamp on the discharge end of the pump case.

4. Remove the liquid end assembly (i.e., liquid end and pump shaft) bypulling the liquid end away from the bearing frame. Be sure the dis-charge end of the liquid end assembly is supported so that the pumpshaft is not bent upon removal.

6.2.2 Installation of Liquid End Assembly

1. Place the shaft key in the pump shaft keyway and be sure it is fully seat-ed.

2. Check to see that anti-seize compound is on the exposed pump shaftwhere it engages with the bearing frame shaft. If not, coat the pumpshaft with a small amount of anti-seize compound (i.e., Never-Seez orAnti-Seize). The anti-seize compound is used to prevent corrosion,galvanic pitting, rust, and seizure. These compounds are availablefrom the factory or local industrial supply house.

3. Align the keyed pump shaft with the bore of the bearing frame shaftand insert the pump shaft such as the key on the pump shaft fits intothe keyway on the bearing frame shaft. Then push until castings cometogether.

4. Fasten together the inlet casting, mechanical seal holder, and bearingframe assembly with the four (4) 3/8-inch bolts and lock washers.Reference Figure 6.5 (liquid end) and Figure 6.6 (mechanical seal) forcorrect placement of parts.

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Figure 6.5Separation of Liquid End From Bearing Frame

5. After fastening the inlet casting to the bearing frame assembly, line upthe set screw hole in the bearing frame shaft with the access hole inthe bearing frame by rotating the flexible coupling. Place the set screwin the bearing frame shaft. Through the opening in the discharge cast-ing, push on the end of the pump shaft with a wooden dowel to seatthe shaft in the bearing frame and then tighten the set screw.

6.3 Mechanical Seal Replacement

STEPS:

1. Remove the liquid end assembly (Section 6.2.1).

2. Remove the pump shaft key and slide the mechanical seal holder off the pumpshaft (Figure 6.7).

3. Remove the rotary portion (spring, washer, and face assembly) of the sealassembly from the pump shaft by rotating and pulling the rotary portion untilit slides off the pump shaft. If prying is required, do not damage the pumpshaft or inlet housing where the seal holder seals (Figure 6.6).

4. When installing a new mechanical seal, do not cut the rubber bellows whensliding the seal over the shaft keyway. One method is to wrap thin plastictape over the shaft keyway to protect the rubber bellows from damage.Wrap 1-1/4 turns to cover the end of the keyway opposite the shaft end.With some overlap, wrap a second 1-1/4 turns, etc., until keyway is com-pletely covered.

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Figure 6.6Removal of Mechanical Seal

5. Lubricate the round surface of the pump shaft with soapy water, oil, petrole-um grease, or silicone grease. After lubrication, install the rotary portion ofthe new seal by placing it onto the pump shaft and carefully rotating and push-ing the rotary portion down the pump shaft until it is lightly seated against thespring. Remove the tape.

6. Remove the stationary portion of the old mechanical seal from the cavity inthe seal holder (Figure 6.6).

7. Lubricate the O-ring on the outside of the new stationary seat. Install the sta-tionary portion into the seal holder cavity. Make sure the stationary portionis fully seated. Lightly lubricate the ground surface of the stationary seat withgrease or oil.

8. Examine the rubber O-ring on the mechanical seal holder and, if the O-ringis damaged, replace it with a new one. A new O-ring is included with the fac-tory supplied mechanical seal replacement kit. Be sure to lubricate beforeinstalling.

9. Place the mechanical seal holder containing the new stationary seat onto thepump shaft and slide it down the shaft until fully engaged with the inlet cast-ing.

CAUTION: Care must be taken not to damage the new stationary seatwhen sliding the assembly over the pump shaft.

10. Install the liquid end assembly onto the bearing frame (Section 6.2.2).

6.4 High Pressure Mechanical Seal Replacement

High pressure mechanical seals have the same basic design as standard mechani-cal seals. Replace them using the same procedure as denoted in Section 6.3.

6.5 Bearing Frame Maintenance on K-Bearing Frame Tonkaflo Pumps

6.5.1 Disassembly of Pumps with K-Bearing Frames

STEPS:

1. Remove the liquid end assembly (Section 6.2.1).

2. Drain the oil from the bearing frame by removing the oil drain plug onthe lower portion of the bearing frame and then remove the bearingframe from the motor.

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3. Bearing frame overhaul. Refer to Figure 6.7 for construction of typeK-Bearing frames.

4. Remove the four (4) bolts and lock washers that fasten the motoradapter to the motor side of the bearing frame. Separate the adapterfrom the bearing frame.

5. Remove retaining ring #1 from the bearing frame as shown in Figure6.7.

6. Remove the lock nut, lock washer, and flat washer from the bearingframe shaft.

7. Place the bearing frame in a press. Simultaneously press out the oilseal holder and remove bearing cone #2 from the shaft by pressing onthe motor end of the bearing frame shaft. After the oil seal holder isremoved, continue pressing to remove the shaft assembly from thebearing frame. Bearing cone #1 will remain in the shaft. Removal ofbearing cone #1 from the shaft should be done only when replace-ment is necessary.

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Figure 6.7Bearing Fame Overhaul

8. Inspect the bearing cups and cones for any rough surface conditionsand replace both cup and cone when necessary. Pitted and galledrollers and/or bearing cap indicates replacement is necessary. Verylight marks around each roller may occur during “break-in period”from the bearing cage. This is not a problem and bearing replacementis not necessary.

9. To remove the bearing cup(s) from the bearing frame, use a brass orsoft steel rod and hammer to knock them out.

10. Inspect both oil seals and replace if the seals are no longer pliable orif they were leaking.

6.5.2 Assembly of Pumps with Type K-Bearing Frames

6.5.2.1 Assembly of Type K-Bearing Frames

STEPS:

1. If removed, press new bearing cup(s) into the bearing frame,making sure they are fully seated.

2. If removed, press a new bearing cone #1 (Figure 6.7) onto theshaft, holding bearing square with the shaft while starting.Make sure the washer behind bearing cone #1 has beenreplaced.

3. If removed, re-install the oil gallery in between bearing cups #1and #2 making sure it is fully seated.

4. Place the shaft in the bearing frame, making sure it passesthrough the oiler ring. Press on the second bearing cone,holding it square with the shaft while starting. Press until thebearing cone is fully seated against the bearing cup and there isno end play.

5. Re-install the tanged flat washer, lockwasher, and nut. Handtighten the lock nut and lightly set a tan on the lockwasher intoa slot on the lock nut. If desired, a 3/8-16UNC x 3 bolt maybe inserted through a side port in the bearing frame and intothe set screw hole in the end of the bearing frame shaft (Figure6.7) when tightening the lock nut.

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6. Using a press, force bearing cone #2 back against the tangedflat washer by pressing on the motor end of the shaft. Thissets the bearing so that the shaft end play may be checked.

7. Check the end play of the shaft by first simultaneously rotatingand pushing on the shaft to seat the bearings and then bypulling and pushing on the shaft. The end play should be 0.003- 0.006-inches (0.07 - 0.15 mm) using a dial indicator (Figure6.8). End play is 0.006-inch (0.15 mm) or less is difficult to feelby hand. Readily noticeable play means further adjustment isnecessary.

8. If further adjustment is necessary, press bearing cone #2 toreseat it against the bearing cup.

9. Tighten or loosen the lock nut as required. Advancement ofthe nut until the next lockwasher tang is aligned results in0.0008-inch (0.02 mm) less end play. Advancing the locknutuntil the same notch lines up with the next lockwasher tangresults in 0.003-inch (0.08 mm) less end play.

10. Repeat Steps 5 and 6.

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Figure 6.8Setting Bearing Frame Shaft End Play

11. When the end play setting is correct, set one tang of the lock-washer into a slot in the lock nut.

12. Inspect and replace the O-ring on the oil seat holder and onthe end cap if damaged. Replace the oil seals.

13. Re-install the oil seal holder, oil seal, and retaining ring (Figure6.7) making sure the seal and O-ring are lubricated with greaseor oil.

14. Install the motor adapter on the motor end of the bearingframe.

CAUTION: IT IS IMPORTANT NOT TO DAMAGETHE SEAL LIP TO PREVENT OIL LEAK-AGE.

The oil seal rubber must be lubricated with grease or oil andthe shaft keyway must be covered to protect the oil seal fromdamage.

A thin metal sleeve placed over the end of the shaft will suffice.The sleeve should be tapered on the end so the seal can beeasily slipped on the end. As an alternate, thin plastic tape,applied 1-1/4 wrap at a time, can be used to cover the keyway.

15. Install the three (3) 5/16-inch bolts and lockwashers to securethe bearing frame cap.

6.5.2.2 Install the Liquid End and Remount the Pump

STEPS:

1. Install the liquid end on the bearing frame (Section 6.2.2, Steps1-5).

2. Mount the pump on the motor or other mounting positionand tighten the clamp on the discharge support.

3. Lubricate as indicated in Section 3.10.

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6.6 Oil Seal Replacement

Oil leaking around the bearing frame shaft indicates oil seal #2 (Figure 6.7) is leak-ing.

Oil leaking from the ports in the bearing frame near the liquid end indicates oilseal #1 (Figure 6.7) is leaking.

6.6.1 Replacement of Oil Seal #2, Figure 6.7

STEPS:

1. Remove the flexible coupling guard, if installed.

2. Either remove the pump or the motor from the bedplate or othermounting.

3. Remove the flexible coupling flange and key from the bearing frameshaft.

4. Remove the four (4) bolts and lockwashers that fasten the adapter tothe bearing frame. Separate the motor adapter from the bearingframe.

5. Remove the oil seal from the motor adapter. Replace with a new oilseal.

6. Replace the O-ring on the motor adapter if damaged.

7. To prevent damage to the oil seal from the shaft keyway, cover thekeyway in the shaft as described in Section 6.5.2.1, Step 13. Applygrease or oil to the bearing frame shaft.

8. Install the motor adapter onto the bearing frame. Care must be takennot damage the oil seal lip.

9. Re-install the four (4) bolts and lockwashers to fasten the motoradapter to the bearing frame.

10. Re-install the coupling flange so it is flush with the end of the shaft andremount the pump or motor as required.

11. Recheck the oil per Figure 3.4.

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6.6.2 Replacement of Oil Seal #1, Figure 6.7

1. Remove the liquid end assembly from the bearing frame as describedin Section 6.2.1.

2. Remove retaining ring #1 shown in Figure 6.7.

3. Remove the oil seal holder (Figure 6.7), which can be done asdescribed in Section 6.5.1.3, Step 4, or as described here by making asimple fixture. Use two (2) 5/16-18NC bolts and a flat plate (not pro-vided) to bridge across the end of the bearing frame to pull out theseal holder. Drill two (2) holes, 3/8-inch (10 mm) diameter, throughthe flat plate, spacing the holes 3.25-inch (82 mm) apart. Insert two(2) 5/16-18UNC bolts through the plate and turn them into the sealholder’s two (2) coupling nuts provided. (Select bolt length as need-ed to engage coupling nuts.) Tighten the two (2) bolts uniformly topull the seal holder out straight.

4. Remove the oil seal from the seal holder and install a new oil seal. Theseal should be flush with the exterior side of the seal holder.

5. Re-install the oil seal holder and retaining ring in the bearing frame.Make sure the O-ring on the outside of the oil seal holder and the oilseal lip are lubricated before installing. Replace the O-ring if damaged.

6. Install the liquid end and remount the pump (Section 6.2.2, Steps 1 -4).

6.6.3 Replacement of Oil Chamber Bulkhead

The oil chamber bulkhead should be removed to replace the oiler ring.

STEPS:

Removal

1. Remove liquid end. Disassemble the bearing frame (Section 6.5.1).

2. Remove oil gallery from between the bearing cups.

3. Remove the bearing frame vent.

4. Using a long screwdriver or 3/8-inch diameter bar, knock out thebulkhead. Access the bulkhead through the vent hole in the top of thebearing frame. Do not damage the oiler ring.

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Installation

1. Apply a gasket forming sealant to the outside diameter of the newbulkhead.

2. Insert the bulkhead into the bearing frame with the lip outward andpress into place.

3. Assemble the bearing frame (Section 6.5.2).

6.7 Lubrication

6.7.1 Adding Oil

Add oil to the bearing frame by removing the vent and pouring oil in thehole. Maintain the oil level between the “FULL” and “ADD” lines on thesight gauge.

DO NOT OVERFILL THE BEARING FRAME. Setting the initial cold oillevel higher than specified will result in higher oil operating temperaturesand reduced oil life.

6.7.2 Changing Oil

THE RECOMMENDED OIL CHANGE INTERVAL IS 2000 HOURS OFPUMP OPERATION OR SIX MONTHS, WHICHEVER OCCURS FIRST.Refer to Section 3.10 on oil filling.

Before starting, check the static oil level on the sight gauge (Figure 3.4).

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7.0 TONKAFLO SERVICE POLICY - LIQUID END

Section 6.0 in the Tonkaflo Installation, Operation, and Maintenance Manual was writtento assist our customers in performing minor maintenance in the field on Tonkaflo pumps.Proper maintenance will ensure longer pump life and minimize down time. Tonkaflopumps are manufactured to make field repairs on the mechanical seal a quick and easyprocess. Bearing frame overhauls may be done by the customer, a local maintenanceshop, or the factory. If repair at the factory is desired, call the factory for a ReturnGoods Authorization (RGA) number and send the complete pump, with or withoutmotor, to the factory. For motor problems, such as worn out motor bearings, it is rec-ommended that maintenance be done at a local motor repair shop.

Field service of the liquid end, with the exception of mechanical seal replacement, is notrecommended. If a liquid end is damaged by running the pump dry, inadequate flow,excessive deadheading, cavitation, or other reasons, contact a Tonkaflo distributor cer-tified for service or return it with or without motor to the factory for repair. For fastreplacement of standard model pumps, a rebuilt pump may be ordered with or withoutmotor as described in Section 8.0.

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8.0 TONKAFLO PUMP RETURN GOODS AUTHORIZATION (RGA) PROCEDURE

If you wish to return goods for repair, warranty evaluation and/or credit, please haveyour original sales order or invoice available when you call Osmonics. Call (800) 848-1750 and press #6 to speak with Customer Service. An Osmonics Customer Servicerepresentative will provide instructions and a Return Goods Authorization (RGA) num-ber which needs to be clearly written on the outside of the box used to ship your mate-rials. All equipment must be shipped to Osmonics with the freight prepaid by the cus-tomer. Call our Customer Service Center with any questions or issues concerningfreight claims and a representative will discuss your situation.

All materials to be returned must be rendered into a non-hazardous condition prior toshipping.

There are three ways to handle a return: (1) send in the pump for repair and return; (2)purchase a rebuilt pump (standard stock models only) and return the original pump forcredit; or (3) purchase a new pump and when desired, send the defective pump to thefactory for repair and return.

8.1 Out-of-Warranty Pump Failure

8.1.1 Return the pump on an RGA for repair. The pump will be repaired andrepair charges invoiced to the customer. The warranty on repairs isthree months.

8.1.2 Purchase a rebuilt pump from stock at list price with full one-year war-ranty. Return the damaged pump on an RGA for full credit less repaircharges.

8.2 In-Warranty Pump Failure

8.2.1 Return the defective pump to the factory for repair on an RGA within 15days. Osmonics absorbs the cost of repair. The repaired pump will bereturned and remains under warranty for the remainder of the originalwarranty period or three months, whichever is longer.

8.2.2 Order a rebuilt pump from stock at list price and full year warranty.Return the defective pump on an RGA within 15 days. Credit will beissued based on warranty determination.

8.2.3 Osmonics will not restock or issue return credit against a new, non-stock,pump purchase regardless of the warranty status of the failed pump. Anexception will be considered if failure occurs at start-up and there is notime on failed unit. The warranty (Section 11.0) is 12 months from instal-lation or 15 months from receipt, whichever occurs first.

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8.3 Shipping Charges

8.3.1 In-Warranty

Customer pays for shipment to Osmonics, Inc. Osmonics pays one waysurface freight return to customer.

8.3.2 Out-of-Warranty When New Pump is Purchased

Customer pays all shipping charges.

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28

Figure 9.9Dimensions, Pump Only

9.0 DIMENSIONAL DRAWING

29

Figure 10.10Cutaway Drawing

10.0 REPLACEMENT PARTS

10.1 Cutaway Drawing

10.2 Parts List, Standard Models

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ItemNo. Part Description Part No.

1. Clamp,Pump Shell Support 1114375AS8000/13500 1114375AS21000 1122957AS40000 1125359

2. Liquid End Assembly SpecifyModel No.

3. O-ring, 1-7/8 inch ID 11142844. Machine Bolt, 3/8-16 x 1-1/4-inch 11109845. Lockwasher, 3/8-inch 11100126. Seal Holder 11203417. Shaft Key, 1/4 x 1/2-inch 11204458. Retaining Ring N5000-433 11142809. O-ring, 4-1/4-inch ID 111399810. KA/KB-Bearing Frame Assembly 1125246

KC-Bearing Frame Assembly 1125247KE-Bearing Frame Assembly 1125248

11 .Oil Breather 111485112. Roller Bearing, Cup & Cone 112060313 .Lock Washer 111428214. Tanged Washer 111428315. Lock Nut, Left Hand Thread 11597516. Bearing Frame Shaft 112509717. Coupling Flange, Pump

Size 6 1-5/8-inch bore 1114333Size 7 1-5/8-inch bore 1114334Size 8 1 5/8-inch bore 1114335Size 9 1 5/8-inch bore 1115177

18. Coupling SleeveSize 6 1120306Size 7 1121702Size 8 1125111Size 9 1125112

19. Key, Pump Flange 112044420. Bolt, 1/2-13 NC x 1.25 1113973

Bolt, 5/8-11 NC 1.25 112510321. Lockwasher, 1/2-inch 1113104

Lockwasher, 5/8-inch 11165022. Coupling Flange, Motor

Size 6 1-5/8-inch bore 1114333Size 7 1-5/8-inch bore 1114334Size 8 1-5/8-inch bore 1114335Size 8 1-7/8-inch bore 1114336Size 9 1-7/8-inch bore 1115178

ItemNo. Part Description Part No.

23. Bolt, 5/16-18NC x 1/2-inch 111047124. Nut, Lock 111376825. Discharge Support Assembly

(Includes Items 23 & 24)6.25 Centerline, AS8000/13500/12000 11254267.00 Centerline, AS8000/13500/21000 11254278.00, 9.00 CenterlineAS8000/13500/21000 11206007.00 Centerline, AS40000 11251688.00, 9.00 Centerline AS40000 1125169

26. Plug, 1/4 NPTStainless Steel, 316 1115055

28. Mechanical SealStandard - Type 21 1121167[200 psi (13.8 bar), ceramic seat]High Pressure - Type 21 116127[300 psi (20.7 bar), ceramic seat]High Pressure - Type 1 1114326[300 psi (20.7 bar), Ni resist seat)High Pressure - Type 1 1115090[400 psi (27.6 bar), tungstencarbide seat]

28. Set Screw 111376929. Oil Seal CR16085 112104930. Oil Seal Holder Assembly 112072331. Retaining Ring 5100-187 111399932. Washer, Bearing Frame 112037933. Bolt, 1/2 x 13NC Low Profile 111437934. Shim Bearing Frame 112036135. Plug, 3/8 NPT 112203636. Oil Sight Gauge 112511437. Oil Chamber Bulkhead 112035438. Oiler Ring 112511539. O-ring, -244 111399840. Lockwasher, 3/8-inch 111001241. Bolt, 3/8-16NC x 1 111204842. Oil Seal CR 18546 111399643. Motor Adapter, Painted KA/KB 1123382

Motor Adapter, Painted KC 1123383Motor Adapter, Painted KE 1123384

10.3 Accessories for the All-Stainless Series Tonkaflo Pumps

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Part Description Part No.

Retaining Ring Pliers for K Mechanical Seal Retaining Ring 1121717Set Screw for Pump Shaft for D, E, G, H, and K-Bearing Frames 1113769Allen Wrench, 3/16-inch, for Set Screw P/N 1113679 1113770Pump Discharge Screen 1120501Heavy-Duty Hydraulic Oil

12-quart Case (3 gallons) 112068255-gallon Drum 1122159

ISO-Vg, Grade 100, 1 Quart 1120693Anti-Seize Thread Compound 1120110Carbon Bearing, AS8000, AS13500, and AS21000 Pumps 1120386Carbon Bearing, AS40000 Pumps 1125327Center Housing Tool, AS8000, AS13500, and AS21000 Pumps 1120781Discharge Housing Tool, AS8000, AS13500, and AS21000 Pumps 1120781Discharge Housing Tool, AS40000 Pumps 1123153

Mechanical Seal Kit200 psi (13.8 bar), Type 21 Ceramic 1121177300 psi (20.7 bar), Type 1 Ceramic 1120606300 psi (20.7 bar), Type 1 Ni-Resist 1120607400 psi (27.6 bar), Type 1 Tungsten Carbide 1120608

Victaulic Adapters3-inch Victaulic x 3-inch MNPT 304SS 11205893-inch Victaulic x 3-inch MNPT 316SS 11205903-inch Victaulic x 2-inch FNPT 304SS 11205863-inch Victaulic x 2-inch FNTP 316SS 11205873-inch Victaulic x 1-1/2-inch FNPT 316SS 11205884-inch Victaulic x 4-inch MNPT 304SS 11220664-inch Victaulic x 4-inch MNPT 316SS 1122067

10.4 Recommended Spare Parts for Standard Tonkaflo Pumps with K-BearingFrames

Spare Parts for Mechanical Seal Replacement and General Bearing FrameMaintenance

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Part Description Part No. Qty.

Installation, Operating and Maintenance 1125317 1Manual for AS8000, AS13500, AS21000, and AS40000 Series High Pressure Pumps with K-Bearing with K-Bearing Frames

1-inch, Type 21, BF501C1-316SS Mechanical Seal 1121177 1Kit. Inlet Pressure <200 psig (<13.8 bar)

Heavy-duty, Non-detergent Hydraulic Oil, 1120693 1ISO-VG 100 [1-quart (0.95 L)]

Bearing Cup and Cone 1120603 2

10.5 Complete Set of Bearing Frame Replacement Parts

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Part Description Part No. Qty.

Bearing Frame Oil Seal, Motor Side (replaces 1113997) 1121049 1Bearing Frame Oil Seal, Pump Side 1113996 1O-ring for Bearing Frame 1113998 2O-ring for Motor Adapter 1113998 1Bearing Cup and Cone 1120603 2Retaining Ring for Bearing Frame Housing 1114280 1Retaining Ring for Bearing Frame Shaft 1113999 1Lock Nut - Left-Hand Thread 1115975 1Multi-tanged Washer 1114283 1Bearing Frame Shaft - Left-Hand Thread 1125097 1Bearing Frame Shaft Bolt Shims 1120361 3Painted Bearing Frame Housing 1123381 1Bearing Frame Shaft Washer 1120379 1Bearing Frame Shaft Bolt 1114379 1Oil Breather 1114851 1Bearing Frame Shaft Set Screw Cone Point 1113769 1Oil Sight Gauge 1125114 1Oil Drain Plug, 3/8-inch 1122036 1Oil Seal Holder Assembly (w/o Oil Seal, P/N 1113996) 1120723 1

Coupling Flanges (2) and Sleeve (1); Refer to CouplingSize Section

Coupling Key Bearing Frame 1120444 1Pump Shaft Key 1120445 1

Machine Bolts, 5/16 x 18NC x 2-1/2-inch long 1116595 2U.S. Thread (for Oil Seal Holder Removal)

10.6 Bearing Frame Overhaul Tools

1. Two (2) 5/16-inch x 18UNC x 2-1/2-inch long bolts for removal of oil sealholder (K-frame pumps).

2. One (1) 3/8-inch bolt for K-frame pumps to hold bearing frame shaft whenremoving lock nut.

3. One (1) 3/16-inch Allen (hex) wrench for removal of bearing frame shaftscrew.

4. Bearing press (arbor press).5. Dial indicator for setting bearing frame shaft end play.

6. Retaining ring pliers for removal of retaining ring from K-Bearing frame shaft(Truarc L1520 or equivalent).

10.7 Mechanical Seal Change-Out Tools

1. One (1) 3/16-inch Allen (hex) wrench for removal of bearing frame shaft setscrew.

2. 9/16-inch wrench.

10.8 Ordering Parts

Order parts through your local distributor or directly from:

OSMONICS, INC.5951 Clearwater DriveMinnetonka, MN 55343-8995 USATelephone: (952) 933-2277Fax: (952) 933-0141Toll Free: (800) 848-1750

To order parts, the following information is necessary:

1. Pump model number (see pump label).

2. Pump serial number (see pump label).

3. Other nameplate information such as operating temperature, materials ofconstruction, or material code and type of mechanical seal

4. Motor horsepower, motor frame size and enclosure specification.

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5. Part name.

6. Part number.

7. Quantity desired.

8. Specific materials of construction, if any.

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11.0 WARRANTY

TONKAFLO PUMP WARRANTY

Osmonics, Inc. warrants its pumps to be free from defects in design, material or work-manship for a period of 15 months from receipt or 12 months from installation of theproduct, whichever occurs first, when said products are operated in accordance withwritten instructions and are installed properly. If Tonkaflo pumps are altered orrepaired without prior approval of Osmonics, all warranties are void. If any defects ormalperformance occur during the warranty period, Osmonics' sole obligation shall belimited to alteration, repair, or replacement at Osmonics' expense, F.O.B. factory, ofparts or equipment, which upon return to Osmonics and upon Osmonics' examinationprove to be defective. Equipment and accessories not manufactured by Osmonics arewarranted only to the extent of and by the original manufacturer's warranty. Osmonicsshall not be liable for damage or wear to equipment caused by abnormal conditions,excessive temperature, vibration, failure to properly prime or to operate equipmentwithout flow, or caused by corrosives, abrasives or foreign objects. The foregoing war-ranty is exclusive and in lieu of all other warranties, whether expressed or implied,including any warranty of merchantability or fitness for any particular purpose. In noevent shall Osmonics, Inc. be liable for consequential or incidental damages.

PUMP MODEL NUMBER

PUMP SERIAL NUMBER

P/N 1125317 Rev. D

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Corporate Headquarters5951 Clearwater DriveMinnetonka, MN55343-8995USA(952) 933-2277 Phone(952) 933-0141 Fax

Euro/Africa Operations230 rue Robert SchumanZA des UsellesF-77350 Le Mée sur SeineFRANCE+33 1 64 10 2000 Phone+33 1 64 10 3747 Fax

Asia/Pacific Operations1044/8 SOI 44/2Sukhumvit Road PrakanongBangkok 10110THAILAND+66 2 38 14213 Phone+66 2 39 18183 Fax

Call (719) 264-3937 for additional information, (800) 605-6698 in the U.S., or visit www.osmonics.com

© Copyright 2001, Osmonics, Inc.Printed in USA, P/N 1125317 Rev. D

Manufactured in the USA