G900T Manual 1.31

MODELS: G 902 T, G 906 T - Ver.1.3
OPERATING INSTRUCTIONS, INSTALLATION & MAINTENANCE
MANUAL INCLUDING SPARE PARTS LIST
Mody Pumps Inc.
2166 Zeus Court
Bakersfield, CA 93308
Tel.: (661) 392-7600 FAX.: (661) 392-7601
E-Mail: sales@modypump.com
http://www.modypump.com
ISO 9001 Certified
LIFE IS PRECIOUS - THINK SAFETY
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Most accidents can be avoided by using COMMON SENSE.
Please read the operation and maintenance instruction manual supplied with the
pump. If you did not receive one, please call your local distributor before pump
installation.
Do not wear loose apparel that may become entangled in the impeller or other
moving parts.
Always use appropriate safety equipment, such as safety glasses, when working
on the pump or piping.
Pumps build up heat and pressure during operation-allow time for pumps to cool
before handling or servicing.
Only qualified service personnel should install, operate and repair pump.
Keep clear of suction and discharge openings. DO NOT insert fingers in pump
with power connected.
Do not pump flammable or hazardous materials (gasoline, acids, alkalis, etc.)
Do not block or restrict discharge hose, as it may whip or burst catastrophically
under pressure.
Make sure lifting handles/hooks are securely fastened each time before lifting.
Do not lift pump by the power cord under any circumstances.
Do not exceed manufacturer's recommendation for optimum performance, as this
could cause the motor/pump to overheat and lead to premature wear or failure.
Secure the pump in its operating position so it does not tip over, fall or slide.
Keep away from impeller when power is connected.
Submersible Pumps are not approved for use in swimming pools, recreational
water installations, decorative fountains or any installation where human contact
with the pumped fluid is common.
Do not operate pump without adequate protection and safety devices in place.
Always replace safety devices that have been removed during service or repair.
To reduce risk of electrical shock, pump must be properly grounded in
accordance with the National Electric Code and all applicable state and local
codes and ordinances.
To reduce risk of electrical shock, always disconnect the pump from the power
source before handling or servicing.
Any wiring of pumps should be performed by a qualified electrician.
Never operate a pump with a power cord that has frayed or brittle insulation.
Cable should be protected at all times to avoid punctures, cuts, and
abrasions - inspect frequently.
Never handle connected - "hot" power cords with wet hands.
Never operate a pump with a plug-in type power cord without a ground fault
circuit interrupter, adequate overload and short circuit protection.
IMPORTANT Mody Pumps Inc. is not responsible for losses, injury, or death resulting
from a failure to observe these safety precautions, misuse or abuse of pumps or
equipment.
Mody Pumps Inc.:
2166 Zeus Court, Bakersfield, CA 93308 Tel.: (661) 392-7600 Fax: (661) 392-7601
INTRODUCTION
THE “mody” ELECTRIC DRIVEN PORTABLE SUBMERSIBLE PUMPS HAVE BEEN DEVELOPED DUE
TO A LONG FELT NEED OF HAVING A TRULY MAINTENANCE FREE PUMPSET FOR VARIOUS
APPLICATIONS. THE PUMP IS A LIGHTWEIGHT, COMPACT UNIT ENABLING IT TO BE USED IN
MOST SEA-CRAFT AND DIFFICULT LAND INSTALLATIONS. THE UNIT CONSISTS OF A
VERTICAL CENTRIFUGAL PUMP WITH AN IN-BUILT SQUIRREL CAGE, INDUCTION ELECTRIC
MOTOR WHICH IS AVAILABLE FOR VARIOUS ELECTRIC SUPPLY CONFIGURATIONS. THE PUMPED
WATER IS USED AS A COOLING MEDIUM WHICH COOLS THE ELECTRIC MOTOR. THE PUMPSET
CAN ALSO BE USED IN ANY POSITION THUS MAKING IT IDEAL FOR DEWATERING IN
DIFFICULT LOCATIONS.
THE SERVICE LIFE OF A SUBMERSIBLE PUMP DEPENDS MAINLY ON TWO THINGS: THE
DEPENDABILITY OF THE SEALING SYSTEM AND THE WEAR RESISTANCE OF THE PUMP WEAR
PARTS.
ALL “mody” SUBMERSIBLE SUMP PUMPS INCORPORATE A UNIQUE SEALING SYSTEM. THE
CONSTRUCTION CONSISTS OF TWO MECHANICAL SEALS, ARRANGED IN TANDEM, IMMERSED IN
AN OIL BATH. THE COMPLETE PACKAGE IS A PRESSURE COMPENSATED SEALING DEVICE
WHICH ENSURES A MINIMAL PRESSURE DIFFERENTIAL ACROSS THE SEAL FACES,
IRRESPECTIVE OF THE DEPTH SETTING OF THE PUMP OR THE HEAD AGAINST WHICH THE
PUMP IS OPERATING.
IN “mody” SUBMERSIBLE SUMP PUMPS, ALL WEAR PARTS ARE RUBBER LINED/COVERED AND
ARE READILY REPLACEABLE AS NEEDED. BOTH WEAR AND ELECTRICITY CONSUMPTION ARE
STILL FURTHER REDUCED WHEN THE PUMPS ARE FITTED WITH LEVEL CONTROLS FOR
AUTOMATIC STARTING AND STOPPING.
IT IS RECOMMENDED THAT IRRESPECTIVE OF TYPE OF PUMP, ADEQUATE MOTOR PROTECTION
SWITCHGEAR SHOULD BE USED AT THE INSTALLATION. WE STRONGLY RECOMMEND THE USE OF
SUITABLE CONTROL BOXES WHICH ARE AVAILABLE FROM US INCORPORATING ALL REQUIRED
PROTECTION.
IT IS IN THE INTEREST OF THE USER THAT HE GO THROUGH THIS MANUAL IN DETAIL
PRIOR TO USING THE PUMP. THE MANUAL WILL HELP HIM UNDERSTAND THE CONSTRUCTIONAL
FEATURES AND TO OBTAIN TROUBLE FREE SERVICE FROM THE PUMP.
PLEASE NOTE THAT ALL PART NOS. REFERRED TO IN DISMANTLING AND RE-ASSEMBLY ARE
PERTAINING TO MODEL G902T. NUMBERS FOR MODEL G906T ARE INDICATED IN THE
DRAWINGS. THE CONSTRUCTION IS IDENTICAL.
PURPOSE:
THE PUMP HAS BASICALLY BEEN DESIGNED AS A DEWATERING UNIT TO PUMP OUT FLOODED
INSTALLATIONS OR ANY CONDITIONS THAT NEED DEWATERING OF UNWANTED FLUIDS. THE
PUMP HAS BEEN DESIGNED TO HANDLE WATER CONTAMINATED WITH OIL AS WELL AS
ABRASIVE PARTICLES NORMALLY ASSOCIATED WITH RAW WATER. THE MAXIMUM SIZE OF
PARTICLES THAT CAN BE HANDLED IS APPROX. 0.4”
OVERALL DIMENSIONS AND WEIGHT.
OVERALL HEIGHT
43.00”/1100mm (APPROX.)
MAX. DIAMETER
15.75”/400mm (APPROX.)
MAX. WEIGHT (EXCL. CABLE) 425 lbs./193 Kg.
MAINTENANCE SERVICES REQUIRED.
THE FOLLOWING CHECKS TO BE DONE AT INTERVALS INDICATED BELOW:
1. CONDITION OF SEALS TO BE CHECKED AT EVERY 2500 HOURS OF OPERATION BY
ASCERTAINING THE CONDITION OF OIL IN THE SEAL CHAMBER.
2. MONTHLY RUNNING OF PUMP FOR AT LEAST 5/10 MINUTES AND CHECKING OF AMPERES
DRAWN AND INSULATION RESISTANCE. (MIN. INSULATION RES. 1 MEG. OHM. AND MAX.
CURRENT DRAWN AS PER NAME PLATE)
SAFETY PRECAUTIONS.
1. ENSURE THAT THE INSULATION RESISTANCE OF THE MOTOR IS AT LEAST 1 MEG. OHM
BEFORE ENERGIZING THE UNIT.
2. CHECK THAT THE AVAILABLE POWER SUPPLY (VOLTAGE, PHASE, FREQUENCY) MATCHES
WITH THE DETAILS ON THE PUMP NAMEPLATE.
3. ENSURE THAT THE GROUND WIRE IN THE 4 CORE CABLE SUPPLIED WITH THE PUMP IS
SECURELY EARTHED.
4. ENSURE DISCHARGE CONNECTION IS CORRECTLY AND SECURELY FITTED
5. ENSURE DELIVERY HOSE IS FREE FROM KINKS AND SHARP BENDS.
6. DO NOT LIFT OR PULL THE PUMP UNDER ANY CIRCUMSTANCES BY MEANS OF THE CABLE.
THE PUMP MUST BE LOWERED/LIFTED FROM THE AREA TO BE PUMPED BY USING A LIFTING
ROPE ATTACHED TO THE EYEBOLTS PROVIDED ON THE TOP OF THE PUMP.
7. WHEN THE PUMP IS ENERGIZED IT WILL KICK WHICH IS OPPOSITE TO THE DIRECTION
OF ROTATION OF THE IMPELLER. ENSURE THE KICK IS IN THE CORRECT DIRECTION (SEE
THE ARROW MARKED ON THE PUMP). SHIFT ANY TWO PHASES IN POWER SUPPLY IF THE KICK
IS WRONG.
8. DRY RUNNING OF THE PUMP IS NOT DESIRABLE. HOWEVER THE PUMP WILL NOT BE
DAMAGED OR SUFFER ANY ILL EFFECTS IF IT IS RUN DRY FOR SHORT PERIODS (UPTO
APPROX. 10 MINUTES).
9. THE MAXIMUM PUMP SUBMERGENCE RECOMMENDED IS 50 FEET.
10. ENSURE CORRECT RATING H.R.C. BACK UP PROTECTION FUSES ARE INSTALLED IN
POWER CIRCUIT BEFORE STARTING THE PUMP. (REFER TABLE BELOW).
11. THE MAXIMUM SPECIFIC GRAVITY OF PUMPED FLUID SHOULD NOT EXCEED 1.1.
PUMP IS DESIGNED TO OPERATE IN FLUIDS WITH pH from 5 – 8.
12. IF PUMP IS NOT USED AND LYING IN STORAGE FOR MORE THAN 30 DAYS PLEASE
ENSURE THAT THE SEAL FACES ARE NOT GAUGE LOCKED – ROTATE THE IMPELLER/KICK
START THE UNIT ONCE A MONTH. REFER TO INSTRUCTIONS ON DISASSEMBLY/REASSEMBLY OF
MECH. SEALS IN THE EVENT THE FACES HAVE LOCKED.
13. FULL LOAD AMPS AT 460V IS 44AMPS & AT 400V IS 50AMPS
MAINS VOLTAGE AT SITE
HRC FUSE RECOMMENDED
380 VOLTS / 3 PHASE
460 VOLTS / 3 PHASE
80 AMPERES
72 AMPERES
FAULT FINDING IN THE UNIT.
TROUBLE GUIDE
CAUSE
PUMP DOES NOT START.
1.FUSES BLOWN.
2.CABLE DAMAGED
3.NO POWER.
4.BLOCKED IMPELLER.
5.STATOR WINDING BURNT.
1.REPLACE FUSES
2.SHORTEN/REPLACE CABLE
3.CHECK POWER SUPPLY.
4.CLEAN BOTTOM PARTS.
6.REPLACE STATOR/REWIND
1.BLOCKED IMPELLER.
2.IMPELLER ROT.WRONG
3.CONNECTED FOR WRONG
VOLTAGE.
4.VOLTAGE LOW/HIGH
5.CLOGGED STRAINER
6.PUMP RUNNING DRY
7.WATER TOO WARM
(ABOVE 60 DEGREES C)
1.CLEAN BOTTOM PARTS.
2.SHIFT TWO PHASE CONN.
3.CHECK & RECONNECT.
1.IMPELLER ROT.BACKWARD.
2.PUMP WORN DOWN.
3.LONG HOSE AND DIAMETER
TOO SMALL.
4.PRESSURE HEAD TOO HIGH
5.DISCHARGE HOSE TORN
6.LEAKING/CRACKED OUTLET
1.SHIFT TWO PHASE CONN.
2.REPLACE WEAR PARTS
3.CHECK PRESSURE LOSSES
PUMP STARTS BUT STOPS.
PUMP GIVES TOO LITTLE
OUTPUT
REMEDY
OPTIONAL FEATURES INCLUDE START/DELTA START,
OVERLOAD PROTECTION. EXTERNAL CONTROL BOXES
FEATURES. PLEASE CONTACT MODY.
4.CONTACT POWER CO.
5.CLEAN STRAINER
6.SWITCH OFF POWER
7.SWITCH OFF POWER
4.USE PUMPS IN TANDEM.
5.USE NEW HOSE
6.REPL.OUTLET/GASKET.
SEAL PROBE SENSOR OR THERMAL
ARE AVAILABLE FOR THE ABOVE
TECHNICAL DESCRIPTION.
THE MODY SUBMERSIBLE PUMP IS IN ITSELF A COMPLETE PUMPING STATION. BESIDES A
POWER SUPPLY, CONTROL BOX AND A DISCHARGE HOSE NO EXTRA EQUIPMENT IS REQUIRED.
THE COMPLETE PUMPSET IS IN A MODULAR CONSTRUCTION ENSURING GOOD AND SIMPLE
SERVICEABILITY. MAJOR DESIGN FEATURES ARE AS UNDER:
THE MOTOR
A RUGGED ALUMINUM DIE CAST ROTOR DYNAMICALLY BALANCED TO GRADE 2.5 ACCURACY OF
ISO 942. A STAINLESS STEEL SHAFT RUNNING IN TWO BALL BEARINGS. INSULATION CLASS
"H" (180 DEGREES CELSIUS). END WINDINGS DULY EPOXY COATED TO PREVENT
DETERIORATION OF INSULATION EVEN IN EXTREMELY HUMID CONDITIONS. WINDING WIRE IS
DUAL COATED SUITABLE FOR "H" CLASS INSULATION.
THE SEAL CHAMBER
THE HEART OF THE MODY PUMP. TANDEM MECHANICAL, TUNGSTEN CARBIDE V/S TUNGSTEN
CARBIDE SEAL FACES (LOWER SEAL) AND TUNGSTEN CARBIDE V/S TUNGSTEN CARBIDE
(UPPER SEAL), SECONDARY SEALS OF HNBR RUBBER AND METAL PARTS IN STAINLESS
STEEL, RUNNING IN AN OIL BATH, ENCLOSED IN A PRESSURE COMPENSATING RUBBER OIL
BAG - CREATES THE ULTIMATE SEAL SOLUTION. THE DESIGN OPTIMIZES SEAL LIFE AND
ALLOWS FOR SIX MONTHLY (2500 HOURS) SERVICE INTERVALS.
BEARINGS.
TWO ANGULAR CONTACT BALL BEARINGS (IMPELLER SIDE), ARRANGED BACK TO BACK,
FILLED WITH A SPECIAL HIGH TEMPERATURE BEARING GREASE REQUIRING NO PERIODIC
MAINTENANCE WHATSOEVER. THE TOP BEARING IS A SINGLE ROW DEEP GROOVE BALL
BEARING, GREASE FILLED AND SEALED FOR LIFE.
THE HYDRAULIC ELEMENTS.
THE HARDENED STAINLESS STEEL IMPELLER RUNNING AGAINST A RUBBER LINED DIFFUSER
AND WEAR PLATE, CONSTITUTE THE HYDRAULIC ELEMENTS OF THE PUMP.
THE
IMPELLER/DIFFUSER CAN BE ADJUSTED TO MAINTAIN MAXIMUM OUTPUT AFTER USAGE
WITHOUT PARTS REPLACEMENT. IT IS IMPORTANT, HOWEVER, TO MAINTAIN CLEARANCES
BETWEEN THE WEAR PARTS.
CABLE GLAND ASSEMBLY. (REFER DRG.)
THE PUMP IS SUPPLIED WITH 50 FEET CABLE AS STANDARD. THE CABLE IS A 4 CORE EPR
SHEATHED AND INSULATED CABLE CONFORMING TO INT’L STD. THE CABLE IS WATERPROOF
AND CAN BE COMPLETELY SUBMERGED IN WATER. THE CABLE IS TERMINATED IN THE PUMP
AT THE CABLE GLAND. THE GLAND ASSEMBLY SEALS THE CABLE ON THE OUTSIDE SHEATH AS
WELL AS A WATER DAM ARRANGEMENT IS PROVIDED WHICH SEALS THE INDIVIDUAL CORES OF
THE CABLE. THIS FEATURE IS UNIQUE AND IS ESSENTIAL TO PREVENT WATER SEEPING
THROUGH THE CORES OF THE CABLE INTO THE MOTOR CHAMBER IN THE EVENT OF A CUT
CABLE. THE CABLE IS ALSO SHEATHED FOR THE FIRST ONE METER BY MEANS OF A CABLE
GRIP MADE OF STAINLESS STEEL. THIS IS ESSENTIAL TO ENSURE THAT THERE IS NO
UNDUE STRAIN ON THE CABLE IF THE PUMP IS PULLED OR LOWERED INADVERTENTLY BY
MEANS OF THE CABLE. COMPLETE DETAILS OF THE CABLE GLAND ASSEMBLY ARE SHOWN IN
THE DRAWING.
GALVANIC CORROSION PROTECTION (FOR SEA-WATER DUTY PUMPS ONLY)
THE PARTS OF THE "MODY" SUBMERSIBLE PUMP THAT ARE IN CONTACT WITH SEA- WATER
ARE PRIMARILY OF STAINLESS STEEL AND ALUMINUM. AS SEA-WATER IS AN ELECTROLYTE
THE PROBLEM OF GALVANIC CORROSION EXISTS DUE TO THE DIFFERENT ELECTRIC
POTENTIALS OF THE MATERIALS IN FLOWING SEA-WATER. TO PREVENT THIS, THE PUMPS
ARE EQUIPPED WITH ZINC ANODES FIXED ON THE OUTER CASING AND DIFFUSER. ZINC,
BEING THE LESS "NOBLE" METAL (MORE NEGATIVE POTENTIAL) GETS CORRODED THUS
PREVENTING CORROSION OF ALUMINUM AND STEEL. IT IS HOWEVER NECESSARY TO INSPECT
THE CONDITION OF THE REPLACEABLE ANODES PERIODICALLY AND REPLACE WHENEVER
NECESSARY. (TYPICALLY INSPECTION ONCE A YEAR SHOULD SUFFICE)
NON REPAIRABLE ITEMS
1. ALL "O" RINGS TO BE REPLACED WHENEVER PARTS ARE DISMANTLED.
2. SEAL ELASTOMER PARTS SHOULD NEVER BE RE-USED AFTER DIS-ASSEMBLY.
3. DO NOT REFILL BEARING GREASE. NEW BEARINGS MUST BE INSTALLED WITH SPECIAL
HIGH TEMPERATURE GREASE.
ELECTRICAL INFORMATION.
MOTORS ARE DESIGNED TO OPERATE ON SINGLE VOLTAGE AND FREQUENCY. MAXIMUM
DEVIATION IN VOLTAGE ALLOWED IS +/-6% AND FREQUENCY +/-3%. CHECK NAME PLATE FOR
OPERATING VOLTAGE AND FREQUENCY.
DISMANTLING AND OVERHAULING.
GENERAL OVERHAUL AND OIL CHECK. (REF. DRGS. NO.DW/149/00 (SHEET 1 & 2)
1. ALWAYS REPLACE O-RINGS WITH NEW ONES WHENEVER DISMANTLING AND RE-ASSEMBLING
A PUMP. NEVER RE-USE OLD O-RINGS.
2. ALWAYS ISOLATE THE UNIT BEFORE REMOVING THE CABLE GLAND (59). BE CAREFUL
WITH O-RINGS (67,68,69) AND SEALING SURFACES. PROTECT THE CHAMBER AGAINST RAIN
AND MOISTURE.
3. DISCONNECT STATOR LEADS. SNIP OFF LEAD WIRE CONNECTORS AND UNSCREW EARTHING
SCREW (45). LOOSEN SCREWS (46), REMOVE CABLE GROMMET (61) AND CABLE LEAD
GROMMET (70). CLEAN THE SEALING SURFACES CAREFULLY AND GREASE THE NEW O-RINGS
BEFORE FITTING THE SAME. DO NOT USE THE OLD O-RINGS.
4. LOOSEN HEX BOLTS AND LOCK WASHERS (28,29) AND REMOVE BASE PLATE (27),
STRAINER (26), DIFFUSER CENTER (23), AND DIFFUSER HOLDER (22). PRY OUT DIFFUSER
RING (21) FROM OUTER CASING (13). THE DRAWING SHOWS THESE DETAILS. CHECK BY
HAND THAT THE ROTOR SHAFT IS NOT JAMMED.
5. PLACE THE PUMP ON THE BOTTOM STUDS (19). TAP THE OUTER CASING (13) WITH
NYLON HAMMERS/MALLET TILL IT LOOSENS FROM THE TOP BRACKET (7). SEPARATE THE
OUTER CASING FROM THE TOP BRACKET BY EMPLOYING TWO SCREW DRIVERS AS LEVERS AND
PUSH THE OUTER CASING DOWNWARDS TILL IT STANDS ON THE FLOOR. LIFT THE UNIT BY
THE EYEBOLTS (4) CLEAR OFF THE OUTER CASING.
6. THE SEAL CHAMBER CONTAINS APPROX. 5 LITERS OF OIL. THE LEVEL AND CONDITION
OF THE OIL SHOULD BE CHECKED EVERY SIX MONTHS. UNSCREW THE OIL PLUGS (80) AND
POUR OUT SOME OIL. NOTE THAT THE OIL GETS A SLIGHTLY DARKER SHADE, BUT THIS IS
NORMAL AND IS NO CAUSE FOR WORRY. IF THE OIL IS EMULSIFIED BY WATER, THE SEALS
HAVE WORN OUT AND MUST BE REMOVED FROM THE ROTOR FOR FURTHER ACTION.
7. LAY DOWN THE PUMP AND REMOVE THE REMAINING PARTS. UNSCREW NUT (33) AND
REMOVE LOCK WASHER (34) (USE IMPELLER SPANNER (T7009) TO HOLD IMPELLER WHILE
UNSCREWING NUTS) AND SLIDE OFF IMPELLER (36) FROM SHAFT. THEN REMOVE TRIMMING
SPACERS (37) AND SAND GUARD (76). THE SAND GUARD IS LIGHTLY PRESS FITTED IN THE
SEAL HOUSING (38). THIS CAN BE REMOVED BY MEANS OF A SCREWDRIVER.
8. UNSCREW NUTS (24,25) AND FOUR STUDS (19) AND REMOVE WEAR PLATE (39). THIS
CAN BE EASILY DONE BY INSERTING TWO SCREWDRIVERS BETWEEN WEAR PLATE AND LOWER
BRACKET (17) THUS PRYING THE WEAR PLATE LOOSE. ALL THE PUMP PARTS HAVE BEEN
DISMANTLED. REPLACE WORN PARTS.
9. THE OIL DIAPHRAGM (71) IS NOW IN VIEW. UNSCREW BOTH THE OIL PLUGS (80) AND
DRAIN OUT THE OIL FROM THE OIL CHAMBER. UNSCREW SOCKET HEAD SCREW (18) AND
REMOVE OIL BAG RING (20). TURN OIL DIAPHRAGM INSIDE OUT AND REMOVE SMALL OIL
CLAMP BY UNSCREWING SCREW (73). REMOVE OIL DIAPHRAGM. SLIDE OFF CAP FOR CIRCLIP
(77), OUTER CIRCLIP (78) FROM ROTOR SHAFT AND REMOVE LOWER MECHANICAL SEAL. BE
VERY CAREFUL IN HANDLING THE TUNGSTEN CARBIDE SEAL FACE. LEAVE STATIONARY
TUNGSTEN CARBIDE SEAT IN THE SEAL HOUSING (38). UNSCREW FOUR NUTS (51) AND PULL
OUT SEAL HOUSING (38). THE STATIONARY TUNGTEN CARBIDE SEAL FACE WILL COME OUT
WITH THE SEAL HOUSING. HANDLE THE FACE CAREFULLY. THE UPPER MECHANICAL SEAL IS
NOW IN VIEW. REMOVE THE UPPER SEAL IN THE SAME WAY AS THE LOWER SEAL.
10. REMOVE THE FOUR NOS. DEEP SEATED CAP SCREWS (18) THAT HOLD THE LOWER
BEARING BRACKET AGAINST THE INNER CASING. THERE ARE FOUR NOS. TAPPED THROUGH
HOLES IN THE LOWER BEARING BRACKET. BY USING THE TOOLS (T9504 -- 2 NOS.) THE
LOWER BRACKET COMPLETE WITH THE ROTOR (11), BEARING (82), BEARING COVER (14)
AND TUNGSTEN CARBIDE SEAT WILL COME OUT WITH THE LOWER BEARING BRACKET. REMOVE
BOLTS (84) AND REMOVE BEARING COVER. PULL OUT ROTOR WITH BEARING FROM LOWER
BEARING BRACKET. (IF THIS IS DIFFICULT USE A HAND PRESS TO REMOVE ROTOR FROM
BEARING BRACKET. ENSURE NO DAMAGE TO THE TUNGSTEN CARBIDE SEAT IN BEARING
BRACKET). THE TC SEAT WITH CUP SEAL HOLDER CAN NOW BE PUSHED OUT FROM THE
BEARING SIDE BY GENTLY TAPPING THE SAME. (USE FINGERS OR A NYLON TIPPED LIGHT
HAMMER ONLY).
11. CHECK BOTH UPPER AND LOWER BEARINGS (10 & 82) FOR ANY RADIAL OR AXIAL PLAY
OR ANY ABNORMAL NOISE WHILE SPINNING THE SAME. CHECK FOR ANY LEAKAGE OF GREASE
THROUGH THE SHIELD OF THE UPPER BEARING. IF BEARING SEEMS WORN OUT OR ANY
GREASE LEAKAGE IS OBSERVED, REPLACE BEARING. (DO NOT USE ANY STANDARD BEARING
PROCURED FROM THE MARKET. THE PUMPS USE BEARINGS WHICH ARE PRE-FILLED WITH A
SPECIAL HIGH TEMPERATURE GREASE AVAILABLE FROM US READILY).
12. THE TOP BRACKET (7) IS HELD IN POSITION BY FOUR STUD BOLTS (5) ON THE INNER
CASING. UNSCREW THE NUTS AND REMOVE THE INNER CASING WITH THE HELP OF PULLER
FOR STATOR (T8006). ALTERNATIVELY TWO SCREWDRIVERS MAY BE USED TO PRY THE TOP
BRACKET FROM THE STATOR.
13. THE STATOR IS SHRINK-FITTED IN THE INNER CASING. THE STATOR CAN NOW BE
CHECKED FOR ANY ELECTRICAL FAULTS.
RE-ASSEMBLY OF THE PUMPSET.
THE PUMP CAN BE RE-ASSEMBLED AS PER PROCEDURE GIVEN BELOW. PLEASE HOWEVER NOTE
THE FOLLOWING:
A) ALWAYS REPLACE NEW O-RINGS AND DISCARD OLD ONES.
B) REPLACE NEW LOCK WASHER WHEN RE-ASSEMBLING.
1. THE CHECKED/REPAIRED STATOR IS KEPT UPRIGHT AND THE TOP BRACKET IS AFFIXED
THROUGH THE TWO BOLTS (5).
2. ALL THE ELECTRICAL CONNECTIONS OF THE STATOR LEAD WIRES AND EARTHING WIRE
SHOULD BE SECURE AND INSULATED.
3. SLIDE BEARING COVER (14) ON ROTOR SHAFT.
4. FIT BEARINGS (IF REMOVED OR REPLACED) ON ROTOR SHAFT (USE EITHER A HAND
PRESS OR SHRINK THE SAME -- DO NOT HAMMER THE BEARINGS ON THE SHAFT-- YOU MAY
SCORE/BEND THE SHAFT AND ALSO DAMAGE THE BEARINGS) AND FIT CIRCLIPS ON TOP AND
BOTTOM GROOVES ON SHAFT. (IF THE BEARINGS ARE SHRINK FITTED ON THE SHAFT, HEAT
THE BEARINGS IN OIL TO A MAXIMUM TEMPERATURE OF 120 DEGREES CELSIUS AS A HIGHER
TEMPERATURE WILL LIQUEFY THE GREASE IN THE BEARING AND RENDER THE SAME
UNUSABLE). DO NOT REUSE OLD BEARINGS THAT HAVE BEEN PULLED OFF.
5. SLIDE LOWER BEARING BRACKET (17) ON TO LOWER BEARING AND ALIGN FOUR NOS.
HOLES ON BEARING COVER WITH THE TAPPED HOLES ON LOWER BEARING BRACKET. FIT THE
BOLTS(84) AND TIGHTEN BEARING COVER.
6. FIT COMPLETE ROTOR ASSEMBLY IN STATOR HOUSING GUIDING UPPER BEARING IN TOP
BEARING BRACKET SEAT. TIGHTEN BOLTS. FIT UPPER TC SEAT IN LOWER BEARING BRACKET
(LIGHTLY OIL THE RUBBER SEAT CUP -- ENSURE THE SEAT SITS SQUARE IN THE BRACKET)
AND SLIDE ON UPPER SEAL ASSEMBLY ON ROTOR SHAFT. (USE SEAL ASSEMBLY MANDREL
(T9004) TO ASSIST IN SLIDING BELLOWS ON TO THE SHAFT). LIGHTLY OIL THE ROTOR
SHAFT BEFORE PUSHING BELLOWS ON SHAFT. USE EXTREME CARE SO THAT THE SEAL FACES
ARE NOT DAMAGED. SLIDE ON CIRCLIP (78) AND FIT IN GROOVE ON SHAFT.
7. PRESS HOME BY HAND LOWER SEAL TUNGSTEN CARBIDE SEAT INTO SEAL HOUSING (38).
LIGHTLY OIL THE RUBBER SEAT CUP BEFORE PRESSING IN CAVITY. THE SEAT MUST SIT
SQUARE IN THE HOUSING.
8. FIT SEAL HOUSING (38) INTO LOWER BRACKET AND TIGHTEN NUTS (51).
9. SLIDE ON LOWER SEAL ASSEMBLY ON SHAFT. APPLY LIGHT COAT OF OIL ON SHAFT
BEFORE SLIDING BELLOWS ON THE SAME. (USE SAME SEAL MANDREL AS USED FOR THE
UPPER SEAL TO SLIDE BELLOWS ON SHAFT). FIT CIRCLIP (78) AS FOR THE UPPER SEAL
ASSEMBLY AND INSTALL CAP FOR CIRCLIP (77)
10. PRESS SAND GUARD (76) INTO SEAL HOUSING (USE A HAND PRESS OR USE A NYLON
HAMMER)
11. TURN OIL BAG INSIDE OUT AND FIT OIL BAG "VEE" SECTION INTO GROOVE IN SEAL
HOUSING. USING SMALL OIL BAG CLAMPS AND SCREWS & NUTS, CLAMP THE OIL BAG TO THE
SEAL HOLDER. TURN OIL BAG TO CLAMP THE LARGER SIDE “O” SECTION INTO THE GROOVE
IN THE LOWER BEARING BRACKET IN THE SAME WAY. COMPRESS THE OIL BAG AND SLIDE
THE OIL BAG RING OVER THE OIL BAG TILL IT SEATS AGAINST THE LOWER BEARING
BRACKET. ALIGN THE FOUR HOLES IN THE OIL BAG RING WITH THE TAPPED HOLES IN THE
LOWER BEARING BRACKET AND TIGHTEN THE OIL BAG RING WITH THE HELP OF THE SOCKET
HEAD CAP SCREWS.
12. FIT ONE DRAIN PLUG WITH "O" RING IN LOWER BEARING BRACKET AND FILL OIL IN
THE OIL BAG. PERIODICALLY PRESS THE OIL BAG TO LET AIR ESCAPE SO THAT FILLING
IS PROPER AND NO AIR IS ENTRAPPED IN THE OIL BAG. REPLACE PLUG WITH "O" RING.
13. SLIDE ON WEAR PLATE AGAINST LOWER BEARING BRACKET AND TIGHTEN THE SAME. FIT
KEY (35) ON THE SHAFT AND SLIDE ON IMPELLER. CLEARANCES BETWEEN IMPELLER AND
WEAR PLATE CAN BE ADJUSTED BY MEANS OF THE TRIMMING SPACERS (37). SLIDE ON LOCK
WASHER (34) ENSURING THAT TONGUE OF LOCK WASHER IS IN GROOVE OF THREADING AND
TIGHTEN NUT (33). BEND LOCK WASHER OVER ANY SIDE OF THE HEX NUT. ENSURE THAT
ROTOR SHAFT IS ROTATING FREE.
14. FIT OUTER CASING ON TOP BRACKET WITH "O" RING. FIT DIFFUSER RING AND
DIFFUSER HOLDER AND TIGHTEN NUTS. FIT DIFFUSER CENTER AND ADJUST CLEARANCE
BETWEEN IMPELLER AND DIFFUSER CENTER TO THE MINIMUM BY USING TRIMMING WASHERS
(30). FIX STRAINER, BASE PLATE AND TIGHTEN BOLTS (28)
OIL SPECIFICATIONS
A) SHELL TELLUS 29.
B) EXXON UNIVOLT 61
C) CHEVRON SUPERLA FDA APPROVED # 10
USE NON-CONDUCTING, NON-FOAMING, NON-DETERGENT OIL ONLY
PARTS CATALOG
1. COMPONENTS LIST : AS PER DRAWING NO. DW/149/00 (SHEET 1 & 2)
2. SPECIAL TOOLS :
S.NO. TOOL PART NO.
1.
2.
3.
4.
5.
6.
7.
8.
T7009
T7010(ALT.)
T5204
T9504
T9004
T4102
T8006
T4104
DESCRIPTION
QUANTITY
IMPELLER SPANNER(G902T)
IMPELLER SPANNER(G906T)
NOSE PLIER 8" LONG
SCREW KEY TYPE "T"
SEAL ASSEMBLY MANDREL
BEARING PULLER (SCREW LENGTH 4")
PULLER FOR STATOR
BEARING PULLER (SCREW LENGTH 8")
1
1
1
2
1
1
1
1
3: STANDARD MAINTENANCE TOOLS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
T1109
T1102
T1107
T1104
T1110
T1112
T1108
T3104
T1211
T2104
T2106
D/E SPANNER SIZE 19-22 MM
D/E SPANNER SIZE 6--7 MM
D/E SPANNER SIZE 13-17 MM
D/E SPANNER SIZE 10-13 MM
D/E SPANNER SIZE 22-24 MM
D/E SPANNER SIZE 32-36 MM
D/E SPANNER SIZE 25-28 MM
SCREW DRIVER
RING SPANNER SIZE 32-36
ALLEN WRENCH 6 MM
ALLEN WRENCH 10 MM
1
1
1
1
1
1
1
1
1
1
1
DRAWINGS :
1. SECTIONAL ASSEMBLY (DW/149/00)(SHEET 1)
2. SEALING ARRANGEMENT WITH MATERIAL PARTS LIST (DW/149/00)(SHEET 2)
R: RECOMMENDED SPARES FOR TWO YEARS OPERATION
SR. NO.
DESCRIPTION
1.
2.
3.
4.
5.
6.
7a.
7b.
8.
9.
10.
11.
MECHANICAL SEAL
"O" RING SET
CABLE GROMMET
CABLE LEAD GROMMET
UPPER BEARING
LOWER BEARING
IMPELLER(G902T/60HZ)
IMPELLER (G902T/50HZ)
DIFFUSER CENTER(G902T)
DIFFUSER RING(G902T)
WEAR PLATE
LOCK WASHER
PART NO.
535-021-00
375-006-66
260-044-66
260-024-66
020-011-07
020-010-07
300-060-22
300-059-22
155-003-80
170-004-80
715-014-80
695-006-21
RECOMMENDED QTY.
2
2
2
2
1
1
1
1
1
1
1
2
NOS.
SETS.
NOS.
NOS.
NOS.
SET.
NOS.
NOS.
NOS.
NOS.
NOS.
NOS.
PLEASE CHOOSE IMPELLER/DIFFUSER SET ACCORDING TO PUMP MODEL &
FREQUENCY.
PUMP MODEL G902TE / G906TE
D.NO.
1a
1b
1c
2a
2b
2c
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36a
36b
37
38
39
40
41
42
43
44
45
46
47
48
49
PART #
405-058-21
405-052-21
405-076-21
405-051-21
380-060-66
270-010-21
650-063-21
365-022-21
035-065-30
080-006-08
380-016-66
020-011-07
480-062-00
625-038-30
400-035-04
037-005-30
380-034-66
380-040-66
035-021-30
520-006-21
650-030-21
385-004-30
170-004-80
160-004-01
155-003-80
700-010-21
370-015-21
640-015-21
030-010-04
045-019-21
705-005-21
600-027-21
650-025-21
370-009-21
365-018-21
695-006-21
320-013-22
300-060-22
300-059-22
600-026-21
545-005-45
715-014-80
380-035-66
619-052-00
380-037-66
*
380-042-66
525-019-21
525-012-21
635-009-21
350-022-21
465-006-11
DESCRIPTION
DISCHARGE OUTLET (8" NPT)
DISCHARGE OUTLET (8" BSP)
DISCHARGE OUTLET (8" HOSE)
DISCHARGE OUTLET (6" NPT)
DISCHARGE OUTLET (6" BSP)
DISCHARGE OUTLET (6" HOSE)
"O" RING
LIFTING HOOK
STUD
FLANGED NUT
TOP BRACKET
CIRCLIP
"O" RING
UPPER BEARING
ROTOR COMPLETE
STATOR CASING
OUTER CASING
BEARING COVER
"O" RING
"O" RING
LOWER BEARING BRACKET
SOCKET HEAD SCREW
STUD
OIL BAG RING
DIFFUSOR RING (M902T)
DIFFUSOR HOLDER
DIFFUSOR CENTRE (M902T)
WASHER
HEX NUT
STRAINER
BASE PLATE
HEX HD BOLT
SPRING WASHER
TRIMMING SPACER
STUD
HEX NUT
LOCK NUT
LOCK WASHER
KEY
IMPELLER 60 HZ (G902T)
IMPELLER 50 HZ (G902T)
TRIMMING SPACER
SEAL HOUSING
WEAR PLATE
"O" RING
BARE STATOR
"O" RING
*
"O" RING
EARTHING SCREW
CH.HD.SCREW
ROTATION ARROW
NAME PLATE (CD)
RIVET
VER - 1.3
QTY
1
1
1
1
1
1
1
2
4
8
1
1
1
1
1
1
1
1
1
1
1
8
4
1
1
1
1
8
12
1
1
6
6
AS REQD
8
8
1
1
1
1
1
3
1
1
1
1
1
*
1
1
2
1
1
6
PUMP MODEL G902TE / G906TE
D.NO.
50
51
52
53
54
55
56
57a
57b
58
59
*
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
PART #
650-011-21
370-006-21
700-004-21
430-019-45
380-039-66
155-006-80
170-005-80
300-063-22
300-062-22
227-008-21
230-006-45
660-061-00
662-003-45
260-044-66
600-030-40
235-006-45
065-018-79
085-010-45
650-046-21
380-812-66
380-012-66
380-009-66
260-024-66
150-006-66
395-005-93
525-022-21
370-002-21
085-007-21
515-007-21
600-037-21
080-008-21
535-021-00
520-002-21
380-001-66
020-010-07
080-011-08
045-009-21
365-031-00
365-025-00
010-005-26
520-011-21
375-006-66
DESCRIPTION
STUD
HEX NUT
WASHER
BLANK CAP
"O" RING
DIFFUSER CENTER (G906T)
DIFFUSER RING (G906T)
IMPELLER 60 HZ (G906T)
IMPELLER 50 HZ (G906T)
CABLE GRIP (Order with Gland)
CABLE GLAND (Order with Grip)
CABLE GRIP WITH GLAND
CABLE SUPPORT
CABLE GROMMET
GLAND SPACER
CABLE GLAND BASE
CABLE AWG 06/4 SOOW
CABLE CLAMP
STUD
"O" RING
"O" RING
"O" RING
CABLE LEAD GROMMET
OIL DIAPHRAGM
OIL
PH.PAN HD.SCREW
HEX NUT
OIL BAG CLAMP (SMALL)
SAND GUARD
CAP FOR CIRCLIP
CIRCLIP
MECHANICAL SEAL
OIL PLUG
"O" RING
LOWER BEARING
CIRCLIP
HEX HD BOLT
WIRE NUT CONNECTOR
WIRE NUT CONNECTOR
ZINC ANODE
CAP SCREW
"O" RING SET
VER - 1.3
QTY
6
8
8
1
1
1
1
1
1
1
1
1
1
1
1
1
50'
1
2
1
2
2
1
1
5L
2
4
1 SET
1
1
2
2
2
2
1 SET
1
4
3
2
4
8
1
LIMITED WARRANTY
We warrant to our immediate customer and to the ultimate consumer that products of our manufacture will be free of
defects in material and workmanship under normal use and service for the following time periods, when installed and
maintained in accordance with our instructions.
PUMPS: One (1) year from date of installation or (18) months from date of shipment, whichever occurs first. As used
herein, “the ultimate consumer” is defined as the purchaser who first uses the product after it’s initial installation or, in
the case for product designed for non-permanent installation, the first owner who uses the product. It is the purchaser’s
or any sub-vendor’s obligation to make known to the ultimate consumer the terms and conditions of this warranty. This
warranty gives you specific legal rights, and there may also be other rights which vary from state to state. In the event
the product is covered by the Federal Consumer Product Warranties Law (1) the duration of any implied warranties
associated with the product by virtue of said law is limited to the same duration as stated herein, (2) this warranty is a
LIMITED WARRANTY, and (3) no claims of any nature whatsoever shall be made against us, until the ultimate
consumer, his successor, or assigns, notifies us in writing of the defect, and delivers the product and/or defective part(s)
freight prepaid to our facility or nearest authorized service station. Some states do not allow limitations on how long an
implied warranty lasts, so the above limitation may not apply. THE SOLE AND EXCLUSIVE REMEDY FOR
BREACH OF ANY AND ALL WARRANTIES WITH RESPECT TO ANY PRODUCT SHALL BE TO
REPLACE OR REPAIR AT OUR ELECTION, FOB POINT OF MANUFACTURE OR AUTHORIZED
REPAIR STATION, SUCH PRODUCTS AND/OR PARTS AS PROVEN DEFECTIVE. THERE SHALL BE
NO FURTHER LIABILITY, WHETHER BASED ON WARRANTY, NEGLIGENCE OR OTHERWISE.
Unless expressly stated otherwise, guarantees in the nature of performance specifications furnished in addition to the
foregoing material and workmanship warranties on a product manufactured by Mody, if any, are subject to laboratory
tests corrected for field performance. Any additional guarantees, in the nature of performance specifications must be in
writing and such writing must be signed by our authorized representative. Due to inaccuracies in field testing if a
conflict arises between the results of field testing conducted by or for user, and laboratory tests corrected for field
performance, the latter shall control. Components or accessories supplied by us but manufactured by others are
warranted only to the extent of and by the terms and conditions of the original manufacturer’s warranty.
RECOMMENDATIONS FOR SPECIAL APPLICATIONS OR THOSE RESULTING FROM SYSTEMS
ANALYSES AND EVALUATIONS WE CONDUCT, WILL BE BASED ON OUR BEST AVAILABLE
EXPERIENCE AND PUBLISHED INDUSTRY INFORMATION. SUCH RECOMMENDATIONS DO NOT
CONSTITUTE A WARRANTY OF SATISFACTORY PERFORMANCE AND NO SUCH WARRANTY IS
GIVEN.
This warranty shall not apply when damage is caused by (a) improper installation, (b) improper voltage, (c) lightning,
(d) sand or other abrasive materials, (e) scale or corrosion build-up due to excessive chemical content. Any modification
of the equipment will also void the warranty. We will not be responsible for loss, damage or labor cost due to
interruption of service caused by defective parts. Neither will we accept charges incurred by others without our prior
written approval. This warranty is void if our inspection reveals the product was used in a manner inconsistent with
normal industry practice and/or our specific recommendations. The purchaser is responsible for communication of all
necessary information regarding the application and use of the product. UNDER NO CIRCUMSTANCES WILL WE
BE RESPONSIBLE FOR ANY OTHER DIRECT OR CONSEQUENTIAL DAMAGES, INCLUDING BUT
NOT LIMITED TO LOST PROFITS, LOST INCOME, LABOR CHARGES, DELAYS IN PRODUCTION,
IDLE PRODUCTION, WHICH DAMAGES ARE CAUSED BY ANY DEFECTS IN MATERIAL, AND/OR
WORKMANSHIP AND/OR DELAYS IN SHIPMENT. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY
OTHER EXPRESS OR IMPLIED WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE.
No rights extended under this warranty shall be assigned to any person, whether by operation or otherwise, without our
prior written approval.
Mody Pumps Inc.: 2166 Zeus Court, Bakersfield, CA 93308 Tel.: (661) 392-7600
Fax: (661) 392-7601