TECHNICAL SERVICE MANUAL
Contents
1. m Figure 6 Inner bearing amp snap ring a i MON E Figure EXPLODED VIEW FOR MODELS GG HJ AND HL NAME OF PART ITEM NAME OF PART ITEN 1 Nylonlocknut 6 11 jRotorandshaftassembly 16 3 Ball bearing outer 8 Casing 13 idler bushing 18 Head and pin assembly 4 Setscew 9 jPipepug 14 assembly 19 Headbolts 5 Bearing housing 10 Mechanicalsealassembly 15 O ring GG HL Seal and Bearing Cross section Shaft Snap H HL ONLY Ring Set Screw Rotor amp Shaft FERE dence ee AU Am Ring A E N SO Lock Nut Housing Spring Rotating Seat Stationary Seat Inner Ball Casing Snap Bearing Ring DISASSEMBLY MODELS GG HJ AND HL Before disassembling a pump determine why it needs to be disassembled with the aid of the troubleshooting chart on page 13 Do not disassemble further than necessary and look for sign of wear or damage throughout the process 1 Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump head must be positioned toward and centered between the port connections to allow for proper flow of liquid through pump Figure 1 page 2 Figure 8 Stationary seal element ES Remove head from pump Do not allow idler to fall from idler pin Tilt top o2. SERIAL NUMBER CUSTOMER SALES ORDER NUMBER OTHER REFERENCE APPLICATION AND OR PROBLEM emm ow j ANY ROTOROD O D ROR ROTORTOOTHLENGTH o SSS o o yoo IDLERGUSHINGID IDLERTOOTHLENGTH O saarron S o SHAFTBUSHNGID J o CRESCENTLENGTH ENDCLEARANCE ooo oo COMMENTS amp RECOMMENDATIONS NOTES VICAN TECHNICAL SERVICE MANUAL BULLETIN TSM 190 C DUD HEAVY DUTY BRACKET MOUNTED PUMPS ISSUE A SERIES 190 SIZES GG HJ HL AS AND AK VICAN PUMP warranty The company 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 the company If during said warranty period any products sold by the company prove to be defective in workmanship or material under normal use and service and if such products are returned to the company transportation charges prepaid and if the products are found by the company to be defective in workmanship or material they will be replaced or repaired free of charge F O B the company location The company assumes no liability for consequential damages of any kind and the purchaser by acceptance of delivery assu
3. the seal face with a clean piece of cardboard Figure 8 page 5 Coat the shaft installation sleeve shaft and inside diameter of the rotating seal seat with seal lubricant Place the spring on the rotor hub and with the seal installation sleeve carefully slide the seal seat onto the shaft and into the spring Figure 9 page 5 Remove the seal installation sleeve Start the end of shaft into the inner ball bearing slowly push the shaft through the bearings Continue until there is pressure applied to the seal spring Turn the bearing housing into the casing by hand until the flange is about 1 16 inch away from the casing Because of the size of these threads and the minimum clearance allowed between these threads the installation of this component may be difficult To aid installation tap the casing around the diameter of the bearing housing threads with a hammer while turning the bearing housing Place a plate into the rotor teeth to hold the rotor and shaft assembly from turning Tighten the nylon lock nut onto the shaft Figure 12 page 6 Turn the bearing housing out until the head can be installed without applying pressure to the rotor teeth Install the head and idler assembly on the pump with the o ring seal on the head figure 13 page 6 If the pump head and casing were marked before disassembly simply match up the markings If not be sure the idler pin which is offset in pump head is positioned directly ab
4. Place the spring on the rotor hub and with the seal installation sleeve carefully slide the rotating seat onto the shaft and into the spring Figure 9 page 5 Start the end of shaft into the stationary seat of the seal slowly push the shaft through the casing Continue until there is pressure applied to the seal spring Place the head and idler assembly in the casing temporarily to support the rotor and shaft assembly while pressing the bearings into the casing Place the bearing washer on the shaft and press the inner ball bearing onto the shaft and into the casing figure 15 amp 16 page 8 Place the bearing spacer on the shaft figure 17 page 8 Turn the bearing housing into the casing until the flange is about 1 16 inch away from the casing Press the outer ball bearing into the bearing housing and onto the shaft Figure 18 Remove the head and idler assembly from the casing and place a plate into the rotor teeth to hold the rotor and shaft assembly from turning Figure 12 page 6 Place the lock washer on the shaft and tighten down the lock nut Bend the tab on the lock washer into the closest notch in lock nut and remove the plate from the rotor teeth Figure 19 Install the end cap into the bearing housing and tighten down Turn the bearing housing out so that the head and idler assembly can be installed without applying pressure to the rotor teeth Install the head and idler assembly on the pump with the o ring sea
5. excessive wear and replace if necessary Check the ball bearing for signs of roughness Roughness can be determined by turning the inner and outer race in opposite directions by hand Note if the motion is smooth and free or rough and stiff Smooth and free is desired Replace if necessary Check the casing for wear or damage Most wear occurs between the suction and discharge ports at the topside of the bore where the rotor Spins a Figure 15 Bearing washer ASSEMBLY MODELS AS AND AK 10 11 12 13 14 15 16 17 18 19 20 21 Press the lip seal into the endcap figure 20 page 9 lip facing away from the threads Coat the idler bushing with soapy water and carefully press the idler bushing into the idler with an arbor press Be sure to press the bushing straight and with constant force Starting and stopping the operation will result in cracking Figure 4 page 3 Press the idler pin into the head using the idler and bushing assembly for alignment Figure 5 page 3 Coat the counter bore in the casing and the stationary seal seat with a lubricant as recommended by your seal supplier With the lapped face of the stationary seal seat facing out carefully press the stationary seat into the casing while protecting the seal face with a clean piece of cardboard Figure 8 page 5 Coat the shaft installation sleeve and inside diameter of the rotating seat with the seal lubricant
6. Closing a valve in the piping stopping all flow the pressure gauge on the discharge port of the pump will show the maximum pressure that the relief valve will allow while pump is in operation IMPORTANT In ordering parts for pressure relief valve always give 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 Figure 24 Bonnet Bulletin TSM 190 C Issue A 11 2004 Page 12 of 16 Troubleshooting No Discharge Insufficient Discharge Volume Suction lift too high for liquid handled This is very important on hot or volatile fluids Suction piping too small in diameter or foot valve is to small Wrong rotation Pump internals worn Insufficient Pressure Relief valve set to low Air or gases in the fluid Insufficient volume being pumped Of operation Packing is too loose or the mechanical seal is leaking Leaking Gaskets Wrong rotation Improper clearances in the internals Excessive power requirement Viscosity to high Air or gases in suction piping Viscosity is higher than expected Loss of suction after a period Suction line is leaking letting air into the pump Noisy operation with good Noisy operation with poor or No performance Leaking around the shaft Mechanical seal is damaged or misaligned Pump internals are worn Suction line is not submerged PUMP INSPECTION REPORT DATE PUMP MODEL __
7. hand one complete revolution every 30 days to circulate the oil SUGGESTED REPAIR TOOLS The following tools must be available to properly repair Series 190 pumps These tools are in addition to standard mechanics tools such as open end wrenches pliers screwdrivers etc Most of the items can be obtained from an industrial supply house 1 Soft Headed hammer 2 Allen wrenches Some mechanical seals and set collars 3 Internal and external snap ring pliers 4 Mechanical seal installation sleeve 6 Spanner wrench adjustable pin type for use on end caps Source 482 J Williams amp Co or equal or hammer and punch 7 Brass bar 8 Arbor press Strainers Use a strainer on the suction side of the pump to prevent foreign material from entering the pump causing damage to the gears and casing or lock up the pump Keep the strainer on the suction side of the pump clean and free of debris A blocked strainer will not allow sufficient liquid to reach the pump The lack of liquid reaching the pump will create cavitation Cavitation is when the liquid vaporizes on its way to the pump then returns to a liquid form on the surfaces of the pump This is very noisy damaging to a pump and seriously affects the output Tapered Installation Sleeve Coat the shaft tapered installation sleeve and inner diameter of mechanical seal with lubricant as recommended by your seal supplier oP dS 9
8. pressure to the pump Spray or brush the externals with soapy water and watch for growing air bubbles around the seal fitting and gaskets Relieve the pressure from the pump Carefully disconnect the air supply Remove the plugs or covers from the ports Return the pump to service PRESSURE RELIEF VALVE INSTRUCTIONS G amp Size QoGG 00 Q OY 9 w 4 2 uum T 7 gt 4 l SY s E ZZ i AU MS f f Sd SAP HW Size A QA lt Q lt gt SSS TEM NAME OF PART NAMEOFPART NAMEOFPART OF PART Cap Gasket Adjusting Screw Relief valve port gasket j Locknu 7 6 Spring Guide 9 DISASSEMBLY Mark valve and head before disassembly to insure proper reassembly 1 Remove bonnet 2 Measure and record length of adjusting screw protruding out of the end cap 3 Loosen locknut and back out adjusting screw until spring pressure is released 4 Remove relief valve cap spring guide spring and poppet from valve body Clean and inspect all parts for wear or damage and replace as necessary ASSEMBLY 1 Place the poppet inside the relief valve body The fingers should passes through the hole in the middle of the body Figure 21 Poppet spring amp 2 Place the spring on the poppet
9. sprina retainer 3 Place the spring retainer on the spring with the protruding step inside the spring 4 With 2 gaskets on the face of the body turn the cap into the body and tighten down 5 Install the adjusting screw in the threaded hole in the endcap and turn in until the remainder of the screw sticking out is equal to the measurement taken during the disassembly 6 Lock the adjusting screw into position by turning the locknut onto the adjusting screw and tightening it against the endcap 7 Place the oring over the threads of the endcap 8 Putthe poppet on the endcap 9 Remount the relief valve onto the pump with 2 gaskets Be sure to replace in the same position as it was removed from The Bonnet must always point towards suction side of pump If pump rotation is reversed remove relief valve and turn end for end Refer to Figures 2 3 page 2 PRESSURE ADJUSTMENT If a new spring is installed or if pressure setting of pressure relief valve is to be changed from that which the factory has set the following instructions must be carefully followed Figure 22 Spring amp Retainer 1 Carefully remove the bonnet which covers the adjusting screw 2 Loosen the locknut which locks the adjusting screw so that the pressure setting will not change during operation of pump 3 Install a pressure gauge in discharge line for actual adjustment operation 4 Turn adjusting screw in to increase pressure and out to decrease pressure 5
10. tank relief valve and a jacketed relief valve Pumps equipped with a jacketed head are not available with a relief valve Figure 1 3 If pump rotation is reversed during operation pressure protection must be provided on both sides of pump 4 Relief valve bonnet see page 12 must a ways point towards suction side of pump If pump rotation is reversed remove pressure relief valve and turn end for end Figures 2 and 3 show 2 possible configurations both have side suction and top discharge A right hand pump turns in the opposite direction to the left hand pump 5 Pressure relief valves cannot be used to control pump flow or regulate discharge pressure MAINTENANCE Series 190 pumps are designed for long trouble free service life under a wide variety of application conditions with a minimum of maintenance The points listed below will help provide long service life LUBRICATION All 190 pumps have sealed ball bearings and carbon bushings which do not require lubrication 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 pump is to be stored or not used for six months or more pump must be drained and a light coat of lubricant and rust preventative suitable to the application must be applied to all internal pump parts Lubricate fittings and apply grease to pump shaft extension Rotating the pump shaft by
11. ATION VICAN PUMP A Unit of IDEX Corporation 661 Grove Ave Windsor Ontario N9A 6M3 Canada DANGER BEFORE OPENING ANY VICAN PUMP LIQUID CHAMBER PUMPING CHAMBER RESERVOIR RELIEF VALVE ADJUSTING CAP FITTING ETC BE SURE 1 THAT ANY PRESSURE IN CHAMBER HAS BEEN COMPLETELY VENTED THROUGH SUCTION OR DISCHARGE LINES OR OTHER APPROPRIATE OPENINGS OR CONNECTIONS 2 THAT THE DRIVING MEANS MOTOR TURBINE ENGINE ETC HAS BEEN LOCKED OUT OR MADE NON OPERATIONAL SO THAT IT CANNOT BE STARTED WHILE WORK IS BEING DONE ON PUMP 3 THAT YOU KNOW WHAT LIQUID THE PUMP HAS BEEN HANDLING AND THE PRECAUTIONS NECESSARY TO SAFELY HANDLE THE LIQUID OBTAIN A MATERIAL SAFETY DATA SHEET MSDS FOR THE LIQUID TO BE SURE THESE PRECAUTIONS ARE UNDERSTOOD FAILURE TO FOLLOW ABOVE LISTED PRECAUTIONARY MEASURES MAY RESULT IN SERIOUS INJURY OR DEATH ROTATION Rotary gear pumps operate equally well in a clockwise or counterclockwise rotation The shaft rotation determines which port is suction and which is discharge Port in area where pumping elements gear teeth come out of mesh is suction port PRESSURE RELIEF VALVES 1 Rotary gear pumps are positive displacement 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 or a torque limiting device or a rupture disk 2 There are relief valve options available on pump models Options may include a return to
12. Vi CAN TECHNICAL SERVICE MANUAL 190 HEAVY DUTY BRACKET MOUNTED PUMPS ISSUE A 11 2004 SERIES 190 CONTENTS MODELS GG HL AS and Special Information 2 Maintenance 2 G HL Pump Breakdown Drawing 4 G HL Pump Disassembly 5 G HL Pump Assembly 6 AS AK Pump Breakdown Drawing 7 AS AK Pump Disassembly 8 AS AK Pump Assembly 9 Thrust Bearing Adjustment 10 Pressure Relief Valve Instructions 11 Pressure Adjustment 12 Hydrostatic Test 12 Troubleshooting 13 Pump Inspection Report Form 14 Notes 15 Warranty 16 INTRODUCTION GG 190 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 VICAN representative Always give complete name of part part number and material with model number and serial number of pump when ordering repair parts The pump model number and serial number are on the nameplate In the VICAN model number system basic size letters are combined with series number UNMOUNTED PUMP UNITS Units are designated by the unmounted pump model numbers followed by Arrangement indicating drive style 13 Direct Connected 53 V Belt 70 Commercial Speed Reducer This manual deals only with Series 190 Heavy Duty Pumps Pump specifications and recommendations are listed in Catalog Section 3 series 190 Heavy Duty pumps IEX IDEX CORPOR
13. f head back and down when removing to prevent this If pump is furnished with pressure relief valve remove it from the head and refer to Pressure Relief Valve Instructions page 11 Be careful not to damage the o ring seal between the head and casing 2 Remove idler and bushing assembly from the idler pin 3 Insert a plate between rotor teeth to keep shaft from turning Figure 12 page 6 Remove the lock nut from the shaft Remove the plate from the rotor 4 Loosen the setscrews in the casing at the shaft end and in the end of the bearing housing Figure 24 amp 25 page 10 5 Remove the bearing housing from the casing 6 Remove the shaft snap ring and tap the shaft forward with a soft headed hammer Then pull the shaft out of the inner ball bearing being careful not to damage the mechanical seal Figure 9 Installing the rotating element Remove the stationary element of the seal from the casing and the rotating element from the rotor and shaft assembly 8 Using snap ring pliers remove the inner snap ring through the shaft end of the casing 9 To remove the inner ball bearing support the casing on the shaft end and press the bearing out from the rotor side 10 Remove the snap ring from the bearing housing and press the ball bearing out from the side opposite to the snap ring 11 Clean all parts thoroughly and examine for wear and damage Check idler bushing idler pin gears and head Replace if neces
14. l on the head as shown in figure 13 page 6 If the pump head and casing were marked before disassembly simply match up the markings If not be sure the idler pin which is offset in pump head is positioned directly above the center of the crescent on the head figure 1 page 2 Tighten head capscrews evenly Adjust pump end clearance Refer to End Clearance Adjustment page 10 Pneumatic test the pump Return the pump to service END CLEARANCE ADJUSTMENT Note Cone point setscrews are to be installed in the diameter of the casing The cone does less damage to the threads than the cup point setscrews Figure 23 I 6 7 Note lf the setscrews loose the end clearance will change during operation This will seize the pump or cause the pump to not move any liquid PNEUMATIC TESTING Loosen setscrews in the face of the end cap and on the diameter of the casing Figure 24 and 25 Turn the bearing housing clockwise until the rotor and shaft assembly rubs the head when turned Turn the bearing housing counter clockwise about 1 4 of a turn Check the shaft rotation for rubbing Turn each setscrew in until the tip touches the bottom Evenly tighten all setscrews and check the shaft rotation for any rubbing or binding Re adjust the setscews until the shaft turns freely Seal the ports with pipe plugs or plates and gaskets Be sure to provide a male air line connection to one of the ports Apply air
15. ll from idler pin Tilt top of head back and down when removing to prevent this If pump is furnished with pressure relief valve remove it from the head and refer to Pressure Relief Valve Instructions page 11 Be careful not to damage the o ring seal between the head and casing Remove idler and bushing assembly from the idler pin Remove the end cap with the lip seal Bend the tab on the lock washer out of the notch in the lock nut Insert a plate between rotor teeth to keep shaft from turning Figure 12 page 6 Remove the lock nut and lock washer from the shaft Remove the plate from the rotor teeth Push the shaft out of the pump while supporting the casing on the head mounting surface Be careful not to damage the seal or let the rotor and shaft assembly drop Remove the stationary element of the seal from the casing and the rotating element from the rotor and shaft assembly Loosen the setscrews in the casing at the shaft end and in the end for the bearing housing Figure 24 amp 25 page 10 Remove the bearing housing from the casing Remove the snap ring from the bearing housing and press the bearing out of the housing Remove the bearing spacer from the casing Stand the casing on the bearing end and press the inner bearing out Clean all parts thoroughly and examine for wear and damage Check idler bushing idler pin gears and head Replace if necessary Check all other parts for nicks burrs
16. mes all liability for the consequences of the use or misuse of the company products by the purchaser his employees or others The company will assume no field expense for service or parts unless authorized by it in advance Equipment and accessories purchased by the company from outside sources which incorporated into any company product are warranted only to the extent of and by the original manufacturer s warranty or guarantee if any THIS IS THE COMPANY S SOLE WARRANTY AND 15 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 the company is authorized to alter this warranty IDEX CORPORATION 2004 All Rights Reserved Vican Pump is a registered trademark of Viking Pump of Canada Inc IBEX IDEX CORPORATION VICAN PUMP A Unit of IDEX Corporation 661 Grove Ave Windsor Ontario N9A 6M3 Canada
17. ove the center of the crescent on the head figure 1 page 2 Tighten head capscrews evenly Adjust pump end clearance Refer to END CLEARANCE ADJUSTMENT page 10 EXPLODED VIEW FOR MODELS AS and AK 1 lipseal 8 j Bearingspacer 15 Pipeplug 22 iderpin 2 2 Endcap 9 Ball bearing Inner 16 MechanicalSeal 23 Head 5 BallBearing 12 Relief valve port gasket 19 Idlerbushing y 6 Setscrew 13 Blankngplate 20 Idler and bushing assembly 7 Bearinghousing X 14 R bot 12 Oring AS amp AK Seal and Bearing Cross Section Casing Outer Bearing Grease Fitting Lip Seal IH id SS SOS End DAN NE y 90 2 Inner Bearing Spacer Bearing Set Screw Housing Washer Spacer DISASSEMBLY MODELS AS AND AK Before disassembling a pump determine why it needs to be disassembled 10 11 12 13 14 19 with the aid of the troubleshooting chart on page 13 Do not disassemble further than necessary and look for sign of wear or damage throughout the process Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump head must be positioned toward and centered between the port connections to allow for proper flow of liquid through pump Figure 1 page 2 Remove head from pump Do not allow idler to fa
18. sary Check all other parts for nicks burrs excessive wear and replace if necessary rom 3 12 Check the ball bearing for signs of roughness Roughness can be determined by turning the inner and outer race opposite directions by hand Note if the motion is smooth and free or rough and stiff Smooth and free is desired Replace if necessary Figure 10 shaft snap ring 13 Check the casing for wear or damage Most wear occurs between the suction and discharge ports at the topside of the bore where the rotor spins ASSEMBLY OF MODELS GG HJ AND HL 10 11 12 13 14 15 16 Coat the idler bushing with soapy water and carefully press the idler bushing into the idler with an arbor press Be sure to press the bushing straight and with constant force Starting and stopping the operation will result in cracking Figure 4 page 3 Press the idler pin into the head using the idler and bushing assembly for alignment Figure 5 page 3 Put the inner ball bearing into the casing and install the inner snap ring Figure 6 page 3 For models HJ and HL only install the shaft snap ring Figure 10 page 5 Install the outer ball bearing and the snap ring into the bearing housing Figure 7 page 3 Coat the counter bore in the casing and the stationary seal seat with a lubricant as recommended by your seal supplier Carefully press the stationary seal seat into the casing while protecting
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