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Viking Pump Technical Service Manual 154 for Heavy Duty

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1. IMPORTANT In ordering parts for pressure relief valve always give model number and serial number of pump as it appears on nameplate and name of part wanted When ordering springs be sure to give pressure setting desired SECTION TSM 154 ISSUE C PAGE 9 OF 10 TECHNICAL SERVICE MANUAL HEAVY DUTY BRACKET MOUNTED PUMPS SERIES 4193 AND 493 SIZES GG AL SECTION TSM 154 PAGE 10 OF 10 ISSUE Cc VIKING JREX PUMP Viking warrants all products manufactured by it to be free from defects in workmanship or material for a period of one 1 year from date of startup provided that in no event shall this warranty extend more than eighteen 18 months from the date of shipment from Viking If during said warranty period any products sold by Viking prove to be defective in workmanship or material under normal use and service and if such products are returned to Viking s factory at Cedar Falls lowa transportation charges prepaid and ifthe products are found by Viking to be defective in workmanship or material they will be replaced or repaired free of charge FOB Cedar Falls Ilowa Viking assumes no liability for consequential damages of any kind and the purchaser by acceptance of delivery assumes all liability for the consequences of the use or misuse of Viking products by the purchaser his employees or others Viking will assume no field expense for service or parts unless authorized by it in advance Equipment and acces
2. If shaft cannot be rotated freely turn thrust bearing assembly counterclockwise until shaft can be turned easily To set end clearance 1 While turning rotor and shaft assembly rotate thrust bearing assembly clockwise until noticeable drag occurs This is zero end clearance 2 Mark position of bearing housing with respect to the casing 3 Rotate thrust bearing assembly counterclockwise the distance listed below as measured on outside of bearing housing 4 Tighten two setscrews in face of bearing housing after adjustment is made to secure thrust bearing assembly position For viscosities above 2500 SSU add additional end clearance 0 005 for GG HJ and HL size pumps and DISTANCE IN INCHES END ON O D OF BEARING HOUSING CLEARANCE INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing carbon graphite bushings extreme care must be taken to prevent breaking Carbon graphite is a brittle material and easily cracked If cracked the bushing will quickly disintegrate Using a lubricant and adding a chamfer on the bushing and the mating part will help in installation The additional precautions listed below must be followed for proper installation 1 Apress must be used for installation 2 Be certain bushing is started straight 3 Do not stop pressing operation until bushing is in proper position starting and stopping may result in a cracked bushing 4 Check bushing for cracks after installation SECT
3. on Figures 13 and 14 3 Loosen locknut and back out adjusting screw until spring pressure is released 4 Remove bonnet spring guide spring and poppet from valve body Clean and inspect all parts for wear or damage and replace as necessary ASSEMBLY Reverse procedures outlined under Disassembly If valve is removed for repairs be sure to replace in same position Relief valve adjusting screw cap must always point towards suction side of pump If pump rotation is reversed remove relief valve and turn end for end Refer to Figures 5 page 2 DANGER Before starting pump be sure all drive equipment guards are in place Failure to properly mount guards may result in serious injury or death PRESSURE ADJUSTMENT If a new spring is installed or if pressure setting of pressure relief valve is to be changed from that which the factory has set the following instructions must be carefully followed 1 Install a pressure gauge in the discharge line for actual adjustment operation 2 Carefully remove the valve cap which covers the adjusting screw Loosen the locknut which locks the adjusting screw so the pressure setting will not change during operation of the pump 3 Turn the adjusting screw in to increase the pressure and out to decrease the pressure 4 With the discharge line closed at a point beyond the pressure gauge gauge will show the maximum pressure the valve will allow while the pump is in operation
4. valve adjusting screw caps must always point towards suction side of the pump If pump rotation is reversed position of the relief valve must be changed Pressure relief valves cannot be used to control pump flow or regulate discharge pressure For additional information refer to Viking Pump s Technical Service Manual TSM 000 and Engineering Service Bulletin ESB 31 THE PUMP must be installed in a matter that allows safe access for routine maintenance and for inspection during operation to check for leakage and monitor pump operation SPECIAL INFORMATION DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc Be sure 1 Thatany pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings orconnections That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on pump That you know what 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 liquid the Failure to follow above listed precautionary measures may result in serious injury or death ROTATION Viking pumps operate equally well in a clockwise or counterclockwise rotation Shaft rotation determine
5. vented through the suction or discharge lines or other appropriate openings or connections The pump drive system means motor turbine engine etc has been locked out or otherwise been made non operational so that it cannot be started while work is being done on the pump You know what material the pump has been handling have obtained a material safety data sheet MSDS for the material and understand and follow all precautions appropriate for the safe handling of the material BEFORE operating the pump be sure all drive guards are in place DO NOT operate pump if the suction or discharge piping is not connected DO NOT place fingers into the pumping chamber or its connection ports or into any part of the drive train if there is any possibility of the pump shafts being rotated DO NOT exceed the pumps rated pressure speed and temperature or change the system duty parameters from those the pump was originally supplied without confirming its suitability for the new service BEFORE operating the pump be sure that e Itis clean and free from debris e all valves in the suction and discharge pipelines are fully opened All piping connected to the pump is fully supported and correctly aligned with the pump Pump rotation is correct for the desired direction of flow ISSUE C PAGE 2 OF 10 Danger Failure to follow the indicated instruction may result in serious injury Warning In addition to possible seriou
6. ION TSM 154 ISSUE C PAGE 8 OF 10 PRESSURE RELIEF VALVE INSTRUCTIONS KG FLL Va inane 7 aw amr if ann am sA A ali i i L tT Cam ar ozo Ni VALVE GG HJ and HL SIZES VALVE LIST OF PARTS Cap Valve Body Adjusting Screw Spring Lock Nut Poppet Spring Guide Cap Gasket Bonnet FIGURE 13 lt TR i Wize as hSSSSS5 p D Cap Valve Body Adjusting Screw Spring Lock Nut Poppet Spring Guide Cap Bonnet Bonnet FIGURE 14 DISASSEMBLY DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings orconnections That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on pump That you know what 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 liquid the Failure to follow above listed precautionary measures may result in serious injury or death Mark valve and head before disassembly to ensure proper reassembly 1 Remove valve cap 2 Measure and record length of extension of adjusting screw Refer to A
7. TECHNICAL SERVICE MANUAL tcron tsm154 HEAVY DUTY BRACKET MOUNTED PUMPS pace Or 4G SERIES 4193 AND 493 SIZES GG AL ISSUE Cc CONTENTS InthOdUCHON s ox bag ee o we eR Be eS 1 Special Information 0 2 Special Mechanical Seals 2 Disassembly oe oc sos ew ewe ed BRAGA ee 3 ASSEMbDIW i k 24 ce kek ba eee eR ee oe ew 5 Thrust Bearing Adjustment 7 Installation of Carbon Graphite Bushings 7 Pressure Relief Valve Instructions 7 FIGURE 1 GG HJ and HL4193 SERIES Foot Type Unmounted Pump with Flanged Ports INTRODUCTION The illustrations used in this manual are for identification purposes only and cannot be used for ordering parts Obtain a parts list from the factory or a Viking representative Always give complete name of part part number and material with model number and serial number of pump when ordering repair parts The unmounted pump or pump unit model number and serial number are on the nameplate In the Viking model number system basic size letters are combined with series number 4193 and 493 are used to indicate either an unmounted pump or mounted pump unit FIGURE 2 UNMOUNTED PUMP AS AK and AL4193 SERIES Foot Type Unmounted Pump with Flanged Ports GG4193 Units are designated by the HJ4193 unmounted pump model HL4193 numbers followed by a letter s indicating drive style AS4193 AK4193 D Direct Drive AL4193 FIG
8. URE 3 M Horizontal Direct Drive GG HJ and HL493 SERIES Unmounted Pump with Flanged Ports IM Vertical In Line Direct Drive IOM Vertical In Line Direct Drive with Piping Support Hangers This manual deals only with Series 4193 and 493 Heavy Duty Pumps Refer to Figures 1 through 14 for general configuration and nomenclature used in this manual Pump specifications and recommendations are listed in Catalog Section 154 Series 4193 and 493 Heavy Duty Pumps FIGURE 4 AS AK and AL493 SERIES Unmounted Pump with Flanged Ports IDEX CORPORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA SAFETY INFORMATION AND INSTRUCTIONS IMPROPER INSTALLATION OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY OR DEATH AND OR RESULT IN DAMAGE TO PUMP AND OR OTHER EQUIPMENT VIKING S WARRANTY DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION OPERATION OR MAINTENANCE THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION OPERATION OR MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP PUMP MUST BE INSTALLED OPERATED AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES Symbol Legend SECTION TSM 154 A or death BEFORE opening any liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc be sure that e Any pressure in the chamber has been completely
9. cket SECTION TSM 154 ISSUE C PAGE 3 OF 10 DISASSEMBLY DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings orconnections That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on pump That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precautionary measures may result in serious injury or death MECHANICAL SEAL SHAFT CASING BALL BEARINGS Refer to figures 7 amp 8 on page 4 for model to be disassembled and name of parts Models 4193 amp 493 are disassembled and assembled the same The difference between these models is the casings Mark the head and casing before disassembly to ensure proper reassembly NOTE The four valve capscrews valve and gasket must be removed from the GG 4193 493 model before the six head capscrews are removed Remove the head capscrews Remove the head from the pump Do not allow the idler to fall from the idler pin Tilt the top of the head back when removin
10. e 10 Install snap shaft ring in groove in the shaft GG HJ and HL size pump See figure 8 Pack lubrication chamber between inner ball bearing and double row ball bearing in the thrust bearing assembly approximately half full with multi purpose grease NLGI 2 See figures 9 and 10 Pack double row ball bearing with multi purpose grease NLGI 2 and press into bearing housing with shield side toward coupling end of shaft See Figure 9 AS AK and AL size pumps do not use a shielded bearing Install snap ring to hold bearing in place on GG HJ and HL size pumps NOTE OnAS AK and AL size pumps install lip seal in bearing house end cap The lip should face towards end of shaft Put bearing spacer sleeve in lip seal and install in bearing housing and tighten setscrews securely See figure 20 Insert a piece of brass or hard wood through port opening between rotor teeth to keep shaft from turning Start thrust bearing assembly into casing Turn by hand until tight This forces rotor against head Replace and tighten locknut on shaft Remove brass piece or hardwood from port opening Adjust pump end clearance refer to page 7 DANGER Before starting pump be sure all drive equipment guards are in place Failure to properly mount guards may result in serious injury or death SECTION TSM 154 ISSUE C PAGE 7 OF 10 THRUST BEARING ADJUSTMENT See Figures 9 and 10 Loosen two screws in face of thrust bearing assembly
11. g to prevent this Avoid damaging the head gasket Remove the idler and bushing assembly If the the idler bushing needs replacing see Installation of Carbon Graphite Bushings page 7 Remove the locknut from the shaft See Figure 9 or 10 A brass bar or piece of hardwood inserted in the port opening and between the rotor teeth will keep the shaft from turning Loosen the two setscrews in the face of the bearing housing and turn the thrust bearing assembly counterwise and remove from the casing See Figure 9 or 10 Remove the snap ring from the shaft for GG HJ and HL size pumps See Figure 9 Remove the bearing spacer from the shaft for AS AK and AL size pumps See Figure 10 Remove the brass bar or piece of hardwood from the port opening HEAD IDLER PIN RELIEF VALVE CUTAWAY FOR MODELS GG HJ AND HL4193 SECTION TSM 154 ISSUE C PAGE 4 OF 10 CASING FIGURE 7 EXPLODED VIEW FOR MODELS GG HJ AND HL 4193 AND 493 O towne e feme u eat 2 snap Ring Oue oa eemo Jis aen O y 3 at Bearing owe o Peere 1e Heat and ier Pn Ason a Snap RingforShat 10 MechanialSeat 17 capsorew torte s BeaingHousing 14 Rotorand shat Assenby 18 Gaskettor Reret vave e SnapRing ney 12 aereum J ro roerne EA w Ball Bearing Inner Idler and Bushing Assembly Capscrew for Valve FIGURE 8 EXPLODED VIEW FOR MODELS AS AL AND AL 4193 AND 493 a p SealforBearing Housing 11 GasketorRelefva
12. mum of maintenance The points listed below will help provide long service life CLEANING PUMP Keep pump as clean as possible This will facilitate inspection adjustment and repair work and help prevent overlooking a dirt covered grease fitting STORAGE f the pump is to be stored or not used for six months or more the pump must be drained and a light coat of non detergent SAE 30 weight oil must be applied to all internal pump parts Lubricate the fittings and apply grease to the pump shaft extension Viking suggests rotating the pump shaft by hand one complete revolution every 30 days to circulate the oil SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 4193 and 493 pumps These tools are in addition to standard mechanics tools such as open end wrenches pliers screw drivers etc Most of the items can be obtained from an industrial supply house 1 Soft Headed hammer 2 Allen wrenches set screws amp special mechanical seals 3 Snap Ring Pliers INTERNAL Viking P N 2 810 047 999 GG HJ HL 4193 493 EXTERNAL Viking P N 2 810 029 375 GG HJ HL 4193 493 4 Mechanical Seal Installation Sleeve 2 751 001 730 for 0 75 inch seal GG 4193 493 2 751 004 730 for 1 25 inch seal AS AL 4193 493 5 Bearing Locknut Spanner Wrench 2 810 043 375 00 6 Spanner Wrench adjustable pin type for use on bearing housing end cap 2 810 008 375 00 Brass bar Arbor press Standard 5 16 12 point so
13. om nicks burrs and foreign particles that might damage the mechanical seal Scratches on the shaft in the seal area will provide leakage paths under the mechanical seal Use a fine emery cloth to remove scratches or sharp edges ASSEMBLY Standard Mechanical Seal Synthetic Rubber Bellows Type READ CAREFULLY BEFORE REASSEMBLING PUMP The seal used in this pump simple to install and good performance will result if care is taken during installation The principle of mechanical seal is contact between the rotary and stationary members These parts are lapped to a high finish and their sealing effectiveness depends on complete contact Prior to installing rotating portion of mechanical seal prepare rotor and shaft assembly head and idler assemblies and appropriate gaskets for quick assembly Once rotating portion of mechanical seal is installed on rotor and shaft assembly it is necessary to assemble parts as quickly as possible to ensure the 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 Never touch sealing faces with anything except clean hands or clean cloth Minute particles can scratch the seal faces and cause leakage 1 Coat idler pin with non detergent SAE 30 weight oil and place idler and bushing in idler pin on head If replacing a carbon graphite bushing refer to installation of Carbon Graphite Bushings page 7 2 Clean roto
14. r hub and casing seal housing bore Make sure both are free from dirt and grit Coat outer diameter of seal seat and inner diameter of seal housing bore with non detergent SAE 30 weight oil 3 Start seal seat in seal housing bore If force is necessary protect seal face with a clean cardboard disc and gently tap it in place with a hammer using a piece of wood 10 MECHANICAL SEAL ROTARY MEMBER i ti TAPERED SLEEVE COAT WITH LIGHT OIL BEFORE ASSEMBLY FIGURE 11 ROTOR HUB SHAFT MECHANICAL SEAL ROTARY MEMBER FIGURE 12 Place tapered installation sleeve on shaft refer to Figure 11 Sleeve is furnished with GG AS AK and AL size replacement mechanical seals Coat rotor and shaft assembly tapered installation sleeve and inner diameter of mechanical seal rotary member with a generous amount of non detergent SAE 30 weight oil Petrolatum may be used but grease is not recommended Place seal spring on shaft against rotor hub Refer to Figure 12 Slide rotary member lapped contact surface facing away from spring over installation sleeve on shaft until it is against the spring Do not compress the spring Coat the rotor and shaft assembly with non detergent SAE 30 weight oil Taking care not to damage the seal seat start end of shaft in bracket bushing and turn from right to left slowly pushing until the ends of the rotor teeth are just below the face of the casing Leave the rotor in
15. s injury or death failure to follow the indicated instruction may cause damage to pump and or other equipment INSTALL pressure gauges sensors next to the pump suction and discharge connections to monitor pressures USE extreme caution when lifting the pump Suitable lifting devices should be used when appropriate Lifting eyes installed on the pump must be used only to lift the pump not the pump with drive and or base plate If the pump is mounted on a base plate the base plate must be used for all lifting purposes If slings are used for lifting they must be safely and securely attached For weight of the pump alone which does not include the drive and or base plate refer to the Viking Pump product catalog DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is mounted on a pump that is operating AVOID contact with hot areas of the pump and or drive Certain operating conditions temperature control devices jackets heat tracing etc improper installation improper operation and improper maintenance can all cause high temperatures on the pump and or drive THE PUMP must be provided with pressure protection This may be provided through a relief valve mounted directly on the pump an in line pressure relief valve a torque limiting device or a rupture disk If pump rotation may be reversed during operation pressure protection must be provided on both sides of pump Relief
16. s which port is suction and which is discharge Port in area where pumping elements gear teeth come out of mesh is Suction Port PRESSURE RELIEF VALVES 1 Viking pumps are positive displacement pumps and must be provided with some sort of pressure protection This may be a relief valve mounted directly on the pump an inline pressure relief valve a torque limiting device or a rupture disk 2 There are relief valve options available on these pumps Relief valve options include an internal relief valve anda return to tank valve 3 If pump rotation is to be reversed during operation pressure protection must be provided on both sides of pump 4 Relief valve adjusting screw cap must always point towards suction side of pump If pump rotation is reversed remove pressure relief valve and turn end for end Refer to Figure 5 5 Pressure relief valves should not be used to control pump flow or regulate discharge pressure For additional information on pressure relief valves refer to Technical Service Manual TSM 000 and Engineering Service Bulletin ESB 31 RELIEF VALVE ADJUSTING SCREW CAP SUCTION DISCHARGE FIGURE 5 SPECIAL MECHANICAL SEALS Extra care should be taken in repair of these pumps Be sure to read and follow all special instructions supplied with your pump MAINTENANCE Series 4193 and 493 pumps are designed for long trouble free service life under a wide variety of application conditions with a mini
17. sories purchased by Viking from outside sources which are incorporated into any Viking product are warranted only to the extent of and by the original manufacturer s warranty or guarantee if any THIS IS VIKING S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED WHICH ARE HEREBY EXCLUDED INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE No officer or employee of IDEX Corporation or Viking Pump Inc is authorized to alter this warranty WARRANTY IREX IPEX CORPORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA 5 2007 Viking Pump Inc All rights reserved
18. this position Withdrawal of rotor and shaft may displace the carbon seal rotating face and result in damage to the seal Place O ring gasket on head and install head and idler assembly on pump Pump head and casing were marked before disassembly to ensure proper reassembly If not be sure idler pin which is offset in pump head is positioned toward or equal distance between port connections to allow for proper flow of liquid through pump 11 12 13 14 15 16 17 18 19 Tighten head capscrews evenly If pump was equipped with a relief valve and was removed during disassembly install with new o rings or gaskets Relief valve adjusting screw cap must always point towards suction port Refer to Figure 5 page 2 For relief valve repair or adjustments see PRESSURE RELIEF VALVE INSTRUCTIONS Page 7 In 2005 the use of single seal bearings were phased out Pumps now use Sealed for Life bearings that have seals on both sides The new bearings can be installed either side first and do not need to be packed with grease For older models with single seal bearings pack the inner ball bearing with multi purpose grease NLGI 2 NOTE AS AK and AL size pumps do not have a snap ring a bearing retainer washer must be assembled over end of shaft before the bearing is assembled See figure 10 Place bearing spacer over shaft and against single row ball bearing in casing AS AK and AL size pumps See figur
19. ve 19 heasse 5 Barsearng owe 12 Roiera fo aen U y e BeaingHousng 1 Peers a erenv CS 7 Bearna Speer 1 Capecrewaforvae 22 Head ana iaer Piney 15 Ror ard shattassenby 23 Canserews orHead SECTION TSM 154 ISSUE C PAGE 5 OF 10 8 Ball Bearing Inner INNER BALL BEARING BALL BEARING OUTER SNAP RING LOCKNUT BEARING HOUSING SETSCREW THRUST BEARING ASSEMBLY GG HJ AND HL SIZES BALL BEARING SHAFT LOCKNUT BEARING HOUSING SETSCREW THRUST BEARING ASSEMBLY AS AK AND AL SIZES 11 The rotor and shaft assembly can now be removed by tapping on the end of the shaft with a lead hammer or if using a regular hammer use a piece of hardwood between the shaft and hammer The spring and rotary mnt INIT BEARING SPACER aR NY ZZS r eTeE are LL sala fi WX LL ZINA AG 1 RAN IK Gm ah Level i snar i KIN BS KRN l SHAFT SNAP RING INNER SNAP RING FIGURE 9 BEARING RETAINER WASHER INNER BALL BEARING Z KA he TTS LT MSS SSS DN NS Q SSS ANAN FIGURE 10 member of the seal will come out with rotor and shaft 12 Remove the inner snap ring and single row ball bearing from the casing See figure 9 The AS AK amp AL size pumps do not have this snap ring 13 Remove the bearing retainer washer from the AS AK or AL size pumps See figure 10 14 Remove the seal seat or stationar
20. y part of seal from casing 15 Disassemble thrust bearing assembly Remove outer snap ring from bearing housing for GG HJ or HL size pumps and ball bearing can be removed See figure 9 16 The AS AK and AL thrust bearing assembly has an end cap and lip seal that can be removed after loosening two set screws in flange of bearing housing Remove ball bearing See figure 10 SECTION TSM 154 ISSUE C PAGE 6 OF 10 The casing should be examined for wear particularly in the area between ports All parts should be checked for wear before pump is put together When making major repairs such as replacing a rotor and shaft it is advisable to also install a new mechanical seal head and idler pin idler and bushing See Installation of Carbon Graphite Bushings page 7 Clean all parts thoroughly and examine for wear or damage Check lip seals ball bearings bushing and idler pin and replace if necessary Check all other parts for nicks burrs excessive wear and replace if necessary Wash the bearings in clean solvent Blow out the bearings with compressed air Do not allow the bearings to spin turn them slowly by hand Spinning the bearings will damage the race and balls Make sure the bearings are clean then lubricate with non detergent SAE 30 weight oil and check for roughness Roughness can be determined by turning the outer race by hand Replace the bearings if they have roughness Be sure the shaft is free fr

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