User manual | 4060

Manual Index
DEMING
®
INSTALLATION, OPERATION & MAINTENANCE MANUAL
End Suction Centrifugal Pumps
Series: 4060
Semi-Open Impeller
Series: 4160
Enclosed Impeller
IMPORTANT!
A Crane Co. Company
Read all instructions in this manual before operating pump.
As a result of Crane Pumps & Systems, Inc., constant product improvement program,
product changes may occur. As such Crane Pumps & Systems reserves the right to
change product without prior written notification.
420 Third Street
Piqua, Ohio 45356
Phone: (937) 778-8947
Fax: (937) 773-7157
www.cranepumps.com
83 West Drive, Bramton
Ontario, Canada L6T 2J6
Phone: (905) 457-6223
Fax: (905) 457-2650
Form No. 120002-Rev. D
CONTENTS
SAFETY FIRST ................................................................................3
A.
GENERAL INFORMATION...............................................................4
Receiving, Storage, Service Centers
B.
INSTALLATION ................................................................................4 - 6
Foundation, Mounting, Field Alignment, Grouting, Piping
Wiring, Rotation, Cooling, Lubrication
C.
OPERATION.....................................................................................7
Priming, Starting, Adjustment
D.
MAINTENANCE ...............................................................................7 - 10
Inspection, Lubrication, Impeller Adjustment, Packing Box Care,
Disassembly, Reassembly
E.
LOCATING TROUBLE .....................................................................11
CROSS-SECTIONS & PARTS LIST.................................................12 - 13
WARRANTY & RETURNED GOODS ..............................................15
Other brand and product names are trademarks or registered trademarks of their respective holders.
Deming® is a registered trademark of Crane Pumps & Systems, Inc.
1996, 11/06
2
Alteration Rights Reserved
SAFETY FIRST!
Please Read This Before Installing Or Operating Pump.
This information is provided for SAFETY and to PREVENT
EQUIPMENT PROBLEMS. To help recognize this information,
observe the following symbols:
WARNING ! Do not wear loose clothing that may
become entangled in moving parts.
WARNING ! Keep clear of suction and discharge
openings. DO NOT insert fingers in pump with power
connected.
IMPORTANT! Warns about hazards that can result
in personal injury orIndicates factors concerned with
assembly, installation, operation, or maintenance which
could result in damage to the machine or equipment if
ignored.
Always wear eye protection when working on pumps.
CAUTION! Warns about hazards that can or will cause minor
personal injury or property damage if ignored. Used with symbols
below.
Make sure lifting handles are securely fastened each
time before lifting. DO NOT operate pump without safety
devices in place. Always replace safety devices that
have been removed during service or repair. Secure the
pump in its operating position so it can not tip over, fall
or slide.
WARNING! Warns about hazards that can or will cause serious
personal injury, death, or major property damage if ignored. Used
with symbols below.
Hazardous fluids can
cause fire or explosions, burnes or death
could result.
Biohazard can cause
serious personal injury.
Rotating machinery
Amputation or severe
laceration can result.
Extremely hot - Severe
burnes can occur on contact.
DO NOT exceed manufacturers recommendation for
maximum performance, as this could cause the motor
to overheat.
Hazardous fluids can Hazardous pressure, eruptions or explosions could cause personal
injury or property damage.
WARNING ! To reduce risk of electrical shock, all wiring
and junction connections should be made per the NEC
or CEC and applicable state or province and local
codes. Requirements may vary depending on usage
and location.
Hazardous voltage can
shock, burn or cause death.
Only qualified personnel should install, operate and repair
pump. Any wiring of pumps should be performed by a qualified
electrician.
WARNING! Products returned must be cleaned,
sanitized, or decontaminated as necessary prior to
shipment, to insure that employees will not be exposed
to health hazards in handling said material. All Applicable
Laws And Regulations Shall Apply.
WARNING ! To reduce risk of electrical shock, pumps and
control panels must be properly grounded in accordance
with the National Electric Code (NEC) or the Canadian
Electrical Code (CEC) and all applicable state, province,
local codes and ordinances. Improper grounding voids
warranty.
Bronze/brass and bronze/brass fitted pumps may
contain lead levels higher than considered safe for
potable water systems. Lead is known to cause cancer
and birth defects or other reproductive harm. Various
government agencies have determined that leaded
copper alloys should not be used in potable water
applications. For non-leaded copper alloy materials of
construction, please contact factory.
WARNING! To reduce risk of electrical shock, always
disconnect the pump from the power source before
handling or servicing. Lock out power and tag.
WARNING! Operation against a closed
discharge valve will cause premature bearing
and seal failure on any pump, and on end
suction and self priming pump the heat build
may cause the generation of steam with resulting dangerous
pressures. It is recommended that a high case temperature
switch or pressure relief valve be installed on the pump body.
Crane Pumps & Systems, 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.
CAUTION ! Pumps build up heat and pressure
during operation-allow time for pumps to cool
before handling or servicing.
WARNING ! Do not pump hazardous materials
(flammable, caustic, etc.) unless the pump is specifically
designed and designated to handle them.
3
A - GENERAL INFORMATION
TO THE PURCHASER:
Congratulations! You are the owner of one of the finest
pumps on the market today. These pumps are products
engineered and manufactured of high quality components.
With years of pump building experience along with a
continuing quality assurance program combine to produce
a pump which will stand up to the toughest applications.
Check local codes and requirements before installation.
Servicing should be performed by knowledgeable pump
service contractors or authorized service stations.
RECEIVING:
Upon receiving the pump, it should be inspected for
damage or shortages. If damage has occurred, file a claim
immediately with the company that delivered the pump.
If the manual is removed from the crating, do not lose or
misplace.
STORAGE:
Short Term - Pumps are manufactured for efficient
performance following long inoperative periods in storage.
For best results, pumps can be retained in storage, as
factory assembled, in a dry atmosphere with constant
temperatures for up to six (6) months.
Figure 1. Foundation Bolt Location and Anchorage
2. MOUNTING:
Pumps and drivers that are received from the factory
with both machines mounted on a common base plate,
were accurately aligned before shipment. All baseplates
are flexible to some extent and, therefore, must not be
relied upon to maintain the factory alignment. Preliminary
alignment is necessary after the complete unit has been
leveled on the foundation, and again, after the unit is
piped, and rechecked periodically as outlined in the
following paragraphs.
Long Term - Any length of time exceeding six (6) months,
but not more than twenty four (24) months. The units
should be stored in a temperature controlled area, a roofed
over walled enclosure that provides protection from the
elements (rain, snow, wind blown dust, etc..), and whose
temperature can be maintained between +40 deg. F and
+120 deg. F. Pump should be stored in its original shipping
container and before initial start up, rotate impeller by hand
to assure seal and impeller rotate freely.
Position unit on foundation and level the base plate,
using rectangular metal blocks and shims, or wedges
having a small taper as shown in Figure 2. A gap of 3/4”
to 1½” should be allowed between the base plate and
foundation for grouting.
SERVICE CENTERS:
For the location of the nearest Deming Service Center,
check your Deming representative or Crane Pumps &
Systems Service Department in Piqua, Ohio, telephone
(937) 778-8947 or Crane Pumps & Systems Canada, Inc.,
Bramton, Ontario, (905) 457-6223.
Adjust the metal supports or wedges until the shafts of
the pump and driver are level. Check the coupling faces,
as well as the suction and discharge flanges of the pump
for horizontal or vertical position by means of a level.
Correct the positions, if necessary, by adjusting the
supports or wedges under the base plate, as required.
B - INSTALLATION
1. FOUNDATION
The pump foundation should be sufficiently substantial
to form a level, rigid support for the combined weight
of the pump and driver and maintain alignment of the
installed unit. Foundation bolts, of the proper size, should
be imbedded in the concrete. A pipe sleeve, about 2½”
diameters larger than the bolt, should be used to allow for
final positioning of the bolts. See Figure 1.
NOTE: A flexible coupling should not be used to
compensate for misalignment of the pump and driver
shafts. The purpose of the flexible coupling is to
compensate for temperature changes and to permit end
movement of the shafts without interference with each
other, while transmitting power from the driver to the pump.
CAUTION! - Remove and lock out power to driver.
4
3. FIELD ALIGNMENT
The faces of the coupling halves should be spaced far
enough apart so that they cannot strike each other when
the driver rotor is moved toward the pump. The necessary
tools for checking the alignment of a flexible coupling are a
straight edge and a taper gauge or a set of feeler gauges.
ANGULAR
MISALIGNMENT
NOTE: In most cases where extreme accuracy is
necessary, a dial indicator may be used to align coupling.
Angular alignment check is made by inserting a taper
gauge or feelers between the coupling faces at 90-degree
intervals around the coupling. The unit will be in angular
alignment when the coupling faces are exactly the same
distance apart at all points. (See Figure 3).
Parallel alignment check is made by placing a straight
edge across both coupling rims at the top, bottom and
at both sides. The unit will be in parallel alignment when
the straight edge rests evenly on the coupling rim at all
positions. Allowance may be necessary for temperature
changes and for coupling halves that are not of the same
outside diameter. Care must be taken to have the straight
edge parallel to the axis of the shafts. Correction for
Angular and Parallel Misalignment is made by adjusting
the shims under the driver. After each change, it is
necessary to recheck the alignment of the coupling halves,
as adjustment in one direction may disturb adjustments
already made in another direction.
PARALLEL
MISALIGNMENT
The permissible amount of coupling misalignment will vary
with the type of pump and driver, but should be limited to
approximately .002 inches per inch of shaft diameter when
final adjustment is made. When the units are lined up cold,
it is necessary to make allowance for the vertical rise of
the driver caused by heating when in operation. When the
preliminary alignment has been completed the foundation,
bolts should be tightened evenly, but not too firmly.
WARNING - Coupling guards must be used to
avoid serious injury to operating personnel.
PERFECT
ALIGMENT
4. GROUTING
Grouting compensates for unevenness in the foundation
and prevents vibration and shifting after mounting is
complete. Build a form around the base plate to contain
the grout, and sprinkle area with water to obtain a good
bond. The base should be completely filled with a good
quality, non-shrinking grout. The usual mixture for grouting
is one part Portland cement and two parts sand with
sufficient water to flow freely. It is also desirable to grout
the leveling pieces, shims or wedges in place. Foundation
bolts should be fully tightened when grout has hardened,
usually about 48 hours after pouring.
Figure 3
5
Figure 4
5. PIPING
The pump suction and discharge connections are not
intended to indicate the required suction and discharge
pipe sizes. The pipe diameter must be selected according
to the requirements of the pumping system and
recommended friction losses for the liquid being pumped.
NOTE: A gate valve in the suction piping should not be
used as a throttling device, as this may cause the liquid to
overheat during operation.
FOOT VALVE
When it is advisable to install a foot valve to facilitate
priming, a spring loaded type check valve must be installed
next to the pump in the discharge line to prevent pump
rupture from water hammer shock. The foot valve should
have a clear passage for water not less than the same
area as that of the suction pipe. Care must be taken to
prevent foreign substances from being drawn into the
pump or chocking the foot valve. For this purpose an
effective strainer should be provided. When there is any
refuse such as sticks, twigs, leaves, etc., in the water, a
large outside screen should be placed around the suction
inlet to prevent chocking of the strainer. This screen should
have sufficient openings so that the flow velocity does not
exceed two feet per second or a free area of four to five
times the suction pipe area.
Usually, it is advisable to increase the size of both the
suction and discharge pipes at the pump nozzles to have
minimum acceptable friction loss, suction pipe should
never be smaller in diameter than the pump suction
nozzle. When suction pipe is of larger diameter than the
pump suction nozzle, an eccentric reducer is required to
eliminate possible air or vapor pockets at the pump suction
inlet.
Both suction and discharge pipes must be supported
independently near the pump, so that when piping is
connected to the pump, no strain will be transmitted to the
pump. Piping should be arranged with as few bends as
possible, and, preferably, with long radius elbow whenever
possible.
6. WIRING
For electric motor drives, connect power supply to conform
with national and local codes. Line voltage and wire capacity
must match the ratings stamped on the motor nameplate.
SUCTION PIPING
A horizontal suction line must have a gradual rise to the
pump. Any high point in the suction pipe can become filled
with air and prevent proper operation of the pump and may
cause loss of prime. The pipe and fittings must be free of
all air leaks.
7. ROTATION
Before starting the pump, check the required direction
of rotation of the pump. The proper direction is indicated
by a direction arrow on the pump casing. Separate the
coupling halves, then start motor to see that it rotates in
the direction required by the pump. If it does not, reverse
any two main leads of the 3-phase wiring to the motor.
The coupling halves can be reconnected and the pump
primed for starting.
Any valves or fittings should located at a distance equal
to 5 to 10 times the diameter of the suction pipe from the
pump suction nozzle. If an elbow must be installed at the
pump suction, it should be installed in a vertical position
to reduce unequal flow into the pump, which may cause
cavitation in the pump.
6
C - OPERATION
2. STARTING THE PUMP
On initial start up, the gate valve in the discharge piping
should be closed and slowly opened after pump is up to
speed and pressure developed. DO NOT operate pump for
any appreciable length of time against a closed discharge
valve, as this may heat trapped liquid excessively and
damage the pump or seal.
The following important items should be checked as pump
is started and placed in operation.
a. Pump and driver securely bolted
b. Coupling properly aligned
c. Piping complete
d. Correct pump rotation
e. Pump shaft turns freely
f. Discharge valve closed
g. Suction valve open (if used)
h. Coupling Guard installed
i. Pump fully primed
j. Pump and driver properly lubricated
k. Seal water valve open (if used)
l. Liquid drips slowly from packing gland
3. PUMP ADJUSTMENT
Open discharge valve as soon as operating speed has
been reached. After the pump has been started the
packing box glands should be tightened to eliminate
excessive liquid loss. (Applies only to pumps having
packed stuffing boxes.) Packing should not be pressed
too tight, as this may result in burning the packing and
scoring the shaft or shaft sleeve. The best adjustment will
allow the liquid to drip slowly from the packing box gland.
This will permit proper lubrication of the shaft and dissipate
generated heat.
Only after these items have been checked should the
pump be started.
As soon as the pump and driver have reached the normal
operating temperature, the unit should be shut down for
final coupling alignment. This should be done by following
the instructions found in Section B, Part 3. If correction
is necessary, it may be accomplished by the addition or
removal of shims from under the motor mounting feet.
1. PRIMING
CAUTION: Before starting the pump, the casing and
suction line must be filled with liquid, and air-vented
through the vent pipe plugs. The pump must not be run
until it is completely filled with liquid, because of danger of
injuring some of the parts of the pump which depend upon
liquid for lubrication.
D. MAINTENANCE
Be sure the stuffing box packing or mechanical seal and
power frame are supplied with the proper lubrication. See
LUBRICATION.
1. INSPECTION
Periodic inspection should be made of the following
components:
a. Bearing lubrication. Make sure the proper grade and
amount of lubrication is present. Section B and
Section D.
b. Packing should be lubricated with the proper
amount and type of acid-resistant lubricant.
c. A double seal should be lubricated with light oil,
clean water, or other compatible lubricating liquid.
d. All piping connections, gasketed joints and drains
should be checked for leaks.
e. Check bearings for excessive wear or failure. Worn
bearings may result in shaft run-out requiring
frequent replacement of packing or seal
f. Coupling alignment and lubrication must be
maintained for smooth operation and long coupling
life.
Pump priming may be accomplished by one of the
following methods. The discharge gate valve should be
closed during priming.
PRIMING BY SUCTION PRESSURE
When operating with suction pressure (flooded suction),
remove the pipe plug at the top of the casing and when
pump is filled with liquid, replace plug.
PRIMlNG WITH FOOT VALVE AND STRAINER
A foot valve and strainer may be installed on the lower end of
the suction pipe to keep pump filled with liquid. Incorporate
filler pipe in discharge pipe between pump and check valve.
Remove pipe plug at top of casing, then fill suction pipe and
pump with liquid. When pump is full of liquid, replace plug
and close filler pipe.
CAUTION: When a foot valve and strainer are installed on
the suction pipe, a spring loaded type check valve MUST be
installed next to the pump in the discharge piping to prevent
pump rupture from water hammer shock.
2. LUBRICATION
All pump and component parts have been lubricated at the
factory except pumps with oil lubricated bearings which
must be lubricated by filling oil reservoir through automatic
oiler.
Priming by means of primer pump or ejector, attached to
the pump, will also remove air from suction pipe and pump
casing. When pump is filled with liquid, start motor and
slowly open discharge gate valve.
Subsequent lubrication depends on operating conditions.
Periodic inspection of bearing lubrication is necessary and
additional grease or oil should be added as required.
7
f.
CAUTION: DO NOT over grease bearings or
add excess oil
Reassemble shaft coupling. Place pump in
operation and check power required to be certain
impeller does not rub casing.
The following lubricants are recommended at the operating
temperature indicated:
NOTE: The Fig. 4160 Series with enclosed impeller
normally does not require adjustment of the impeller.
Oil lubricated Bearings - S.A.E. #10 Wt. Non-detergent oil
4. PACKING BOX CARE
Pumps are normally furnished with grease fittings (243)
for packing lubrication and with the internal water seal
passage blocked. If operating with suction lift and clean
liquid the socket type pipe plug (263) may be removed
and the liquid being pumped will then form a water seal at
the lantern ring.
Grease Lubricated Bearings - Shell Alvania #2 or equal.
Packing boxes - Lithium base grease
Double Seal - Pressurized water or light oil circulated
thru seal chamber. If pressurized liquid is not available,
Shell Alvania EPRO #71030 grease may be used with
pressurized grease cup.
Driver and Coupling - See manufacture’s recommendations.
When installing new rings of packing, clean packing box
(11) and inspect parts for any damage. If the shaft sleeve
(14) is worn or grooved, it should be replaced. New
packing will not do an adequate sealing job on a worn
shaft sleeve.
SINGLE SEAL
Pumps with single seals are normally furnished with
an internal by-pass open (See cross section). A small
portion of the liquid being pumped is recirculated from
the casing through the seal chamber to act as a lubricant
and coolant. For hot water service at temperatures above
180ºF the by-pass should be plugged and seal chamber
cooled with water through a heat exchanger or from an
outside source.
Insert two new rings of packing in front of lantern ring.
Stagger joints to minimize leakage. Tamp each ring in
place. Replace lantern ring. Add two rings of packing
behind lantern ring. Replace gland (17) and bolts (209),
rotate shaft and tighten gland securely. Loosen the gland
and add the final ring of packing. Be sure lantern ring is
positioned to receive lubrication through item (243) orifice.
Tighten nuts securely to seat packing and rotate shaft.
After rotating several turns, loosen nuts (210) to finger
tight for starting.
DOUBLE SEAL
On double seal applications, clear liquid under pressure
must be circulated thru the seal chamber at approximately
20 pounds above the maximum pressure that may occur
on the inner seal. This may be accomplished with clear
liquid from outside source, liquid from pump discharge
thru a filter or thru exchanger if liquid is over 180ºF.
IMPORTANT! - Liquid being pumped should drip
slowly but constantly through the packing and
gland. This will prevent overheating, high power
consumption, and shaft sleeve damage.
3. IMPELLER ADJUSTMENT - Fig. 4060 Series
An outstanding feature of this pump is the axial adjustment
of the impeller to compensate for eventual wear or corrosion.
Correct impeller adjustments will insure optimum operating
performance and effiencies.
Lubricate through grease fitting (243) or by removal of
fitting and substituting tubing and on outside source of
water or oil.
5. DISASSEMBLY
The disassembly instructions apply to the series of
pumps in general and may vary slightly on special units.
If complete disassembly is not necessary, use only those
steps which apply.
To adjust impeller clearance:
a. Disconnect power supply to the driver and disengage
shaft coupling.
b. Loosen the three lock nuts and jack screws (204)
and (286) then tighten the three cap screws (213)
evenly, by alternating cap screws, until the impeller
vanes just rub against the casing (1) when the
shaft is rotated by hand. It may be necessary to
bump the shaft on the coupling end to make sure
that the impeller is against the casing.
c. Tighten the jack screws (286), finger tight against the
power frame (19), then loosen cap screws (213).
d. Tighten the jack screws an additional 1/3 turn
(2 hex) to obtain .016” to .020” impeller clearance.
The clearance may be measured with feeler gauge
thru suction inlet of the casing (1).
e. Carefully tighten cap screws (213) and lock nuts
(204) then rotate shaft by hand to make certain that
impeller does not rub against casing.
Close gate valve in discharge and suction piping. Inspect
all parts removed to determine whether suitable reuse. It
is recommended that all packing, gaskets and o-rings be
replaced with new ones during reassembly.
NOTE: Special precautions must be observed when
handling mechanical seals so as not to damage the
lapped faces of the seal.
Unless casing (1) is damaged or it is necessary to replace
wearing ring (7), it may not be necessary to remove the
suction and discharge piping from the casing to service
the power end.
8
a. Disconnect power supply to the motor and remove
motor from baseplate or remove coupling spacer if
spacer type coupling is installed.
b. Remove all cooling or lubricating lines.
c. Remove drain plug (216).
d. Remove cap screws (212) and separate power end
from casing. Fig. 4160 Series - Remove wearing
ring (7) from casing (1) if worn.
e. Remove impeller screw (26), impeller washer (270),
impeller washer gasket (30) and o-ring (272) and
pull impeller (2) from shaft with an impeller or wheel
puller. Remove impeller key (32) from shaft.
f. Loosen gland nuts (210) and remove gland bolts
(209), gland (17) and gland clips (206). The packing
box cover (11) may now be removed from the frame
(19).
g. Remove packing (13) and lantern ring (29) from
packing box cover and clean bore of the cover.
h. If pump is fitted with single mechanical shaft seal,
mark the position of the seal retainer (230) on
the shaft sleeve (14) to assist in reassembly.
Remove seal rotating assembly (89B) from the shaft
sleeve and stationary seal seat (89A) from the
gland (251).
a. Inspect bearings and replace if worn.
b. Press grease retainer (51) onto shaft to position
marked. Press bearing (16) onto shaft until inner
race of bearing is against shaft shoulder.
NOTE: Press only on inner race of bearing. Apply
fresh grease to bearing if grease lubricated.
c. Carefully press bearing (18) into bearing housing
(33) until properly seated in bottom of bearing
housing. Press bearing housing assembly onto
shaft (6) until inner race of bearing is against shaft
shoulder. Apply fresh grease to bearing and bearing
cover if grease lubricated.
d. Insert shaft assembly into frame (19), from the
coupling end, until there is approximately 5/16”
between flange of bearing adapter (33) and end of
frame.
If oil lubricated bearings, apply light oil to exterior of
bearing housing (33) and o-ring (232) and carefully
guide bearing housing into frame to prevent
damage to o-ring.
e. Place bearing lock washer (69) on the shaft and
thread bearing lock nut (22) tight against bearing
lock washer. Bend tangs of washer into bearing
lock nut.
f. Place bearing cover (37) on bearing housing (33)
and replace and tighten cap screws (332). Also
replace cap screws (213) and jack screw with lock
nut (286) and (204) but do not tighten. Replace
shaft key (46) and pump half of flexible coupling
on shaft.
If pump is fitted with double shaft seal, push inboard
stationary seal seat (89A) from packing box cover
(11) and the outboard seal seat (89A) from the seal
gland (251). Remove rotating seal assembly (89B)
from the shaft sleeve (14).
i.
j.
k.
l.
m.
n.
o.
Remove shaft sleeve (14) from pump shaft (6).
Loosen set screws (211) in deflector and remove
deflector (40).
Remove pump half of flexible coupling and key
(46) from pump shaft (6). Remove cap screws
(213), cap screws (332) and jack screws (286) and
pull bearing cover (37) from bearing housing (33).
Open tangs of lock washer (69) and unscrew and
remove bearing lock nut (22) and bearing lock
washer (69).
Insert small pry bar under flange at bearing housing
(33) and carefully force shaft with bearings (18) and
(16), bearing housing (33) and grease retainer (51)
from coupling end of frame (19).
Mark location of grease retainer (51) on the shaft
then press grease retainer and bearing (16) from
impeller end of shaft.
With bearing puller, remove bearing housing (33)
and bearing (18) from coupling end of shaft. Press
bearing from bearing housing.
Wash bearings and bearing cover to remove old
grease. Oil lubricated pumps include o-ring (232) on
bearing housing. Check and replace if nicked or
damaged.
ALL PUMPS WITH PACKING
g. Place packing box cover on bench and insert shaft
sleeve in bore with keyway down. Insert packing as
described in Section D item 3.
h. Position deflector (40) on shaft. Apply Permatex or
Silastic sealing material to end of sleeve which will
seat against shaft shoulder and slide entire packing
box cover assembly (11) onto the shaft and align
keyways.
i. Assemble split gland onto shaft and replace gland
clips (206), bolts (209) and nuts (210).
ALL PUMPS WITH SEALS
Before installing any new seal or replacing old seals,
inspect and clean all parts. Remove all burrs, nicks, etc.,
from shaft and sleeve.
j. Place deflector (40) on shaft and secure. Apply
Permatex or Silastic sealing materials to end of
sleeve that seats on shaft shoulder and slide onto
shaft, lining up keyways.
SINGLE SEAL
CAUTION: Protect the lapped faces of the stationary
seal seat and rotating seal washer during installation.
k. Apply light oil to the outer surface at the stationary
seal seat and o-ring (89A) and press seal seat into
the seal gland (251).
6. REASSEMBLY
Clean and inspect all parts, replacing any worn or damaged
parts, also replace all gaskets and o-rings. Replace
mechanical shaft seal showing worn faces, hardened
elastomer or loss of spring tension.
9
l.
Apply light oil to the inside of the seal bellows and
to the shaft sleeve (14) then slide seal gland (251),
gland gasket (259) and rotating seal assembly
(89B) onto the shaft sleeve. See Figure 5.
m. Place seal retainer (230) on the shaft sleeve to the
premarked position and tighten set screw.
n. Place packing box cover (11) against frame (19), in
proper position, and attach seal gland (251) to
packing box cover with bolts and nuts (209) and
(210), tighten securely.
Figure 5
DOUBLE SEAL
o. Apply light oil to the outer surface of the stationary
seal seats and o-rings (89A) and press one seal
seat into seal gland (251) and the other seal seat
into the packing box cover (11). Slide seal gland
and gland gasket (259) onto the shaft.
(See Figure 6)
p. Apply light oil to the inside of the seal bellows and
shaft sleeve (14) and slide the rotating seat
assembly (89B) onto shaft sleeve.
q. Place packing box cover (11) against frame (19), in
proper position, and attach seal gland (251) to
packing box cover with bolts and nuts (209) and
(210). Tighten securely. Seal may be tested for
leakage by applying 20 pounds of water pressure to
the seal cavity of packing box cover.
ITEM No
DESCRIPTION
11
Packing Box Cover
14
Shaft Sleeve
89A
Shaft Seal - Stationary Seat
89B
Shaft Seal - Rotating Assembly
209
Machine Bolt
210
Hex Nut
230
Seal Retainer
251
Seal Gland
259
Gland Gasket
ALL PUMPS WITH PACKING OR MECHANICAL SEAL
r. Place shaft gasket (38) against shaft sleeve (14)
and replace impeller key (32) in pump shaft keyway.
s. Spread a drop of Loctite #601 on the shaft and
mount impeller (2) on the shaft. Block the coupling
end of the shaft then lay a block of wood over the
impeller vanes and tap lightly on the block until
impeller is seated on the shaft.
t. Assemble the impeller screw o-ring (272), impeller
washer (270) and impeller washer gasket (30) onto
the impeller screw (26). Apply a drop of Loctite
#601 to the impeller screw and mount the assembly
on the end of pump shaft. Tighten securely.
u. Fig. 4160 Series - Clean wearing ring of casing (1)
of any rust or deposits then press new wearing ring
(7) into casing.
Fig. 4060 and 4160 Series - Place casing gasket
(73) on packing box cover (11) and mount casing
(1). Insert and tighten cap screws (212).
NOTE: Casing (1), packing box cover (11) and power
frame must be correctly aligned when reassembled. Be
sure rabbeted flange of packing box cover is fully seated in
power frame and that casing is aligned and fully seated on
packing box cover BEFORE tightening cap screws (212).
v. Adjust impeller clearance according to Section D
item 2.
w. Adjust gland pressure and lubrication packing
according to Section D.
x. Check all lubrication points listed in Section D
item 3.
y. Replace any tubing or outside piping to packing
box cover.
z. Mount pump on baseplate. Reassemble flexible
shaft coupling and check for pump and motor
alignment according to Section B. Verify proper
rotation before placing pump in service.
Figure 6
10
E - LOCATING TROUBLE
5. Pump Takes Too Much Power
a. Speed too high - Compare Pump and motor
nameplates
b. Head lower than rating - pumps too much liquid.
Check system requirements
c. Liquid specific gravity or viscosity greater than
expected. Requires large motor.
d. Pump and driver misalignment - Check casing for
pipe strain. Support piping and realign unit
e. Wrong direction of rotation
f. Electrical defects - Check power supply and motor
g. Mechanical defects
1. Bent pump shaft.
2. Impeller binds in casing - Check impeller
adjustment
3. Stuffing box packing too tight. See Packing
1. No Liquid Delivered
a. Pump not primed - See Priming
b. Speed too low - Check motor speed and nameplate
c. Discharge head too high
d. Impeller completely plugged
e. Wrong direction of rotation - Check wiring
f. Suction head too high - over 15 feet, check with
vacuum gauge.
g. Suction or discharge valves closed
2. Not Enough Liquid Delivered
a. Air leaks in suction piping
b. Speed to low - Check motor speed
c. Discharge head higher than anticipated.
Check discharge valve/system requirements
d. Suction lift too high - over 15 feet, chech with
vacuum gauge.
e. Impeller partially plugged
f. Wrong direction of rotation
g. Not enough suction head for hot liquid
h. Mechanical defects
1. Impeller worn or damaged
2. Casing worn
i. Foot valve too small
j. Foot valve not immersed deep enough
6. Excessive Pump Vibration
a. Cavitation at pump suction due to insufficient
NPSHA. Alter installation to reduce NPSHR
b. Impeller out of balance - Check mechanical
(static) balance
c. Pump and motor misalignment
d. Obstruction in pump impeller
e. Pump shaft bent
f. Worn pump bearings
g. Impeller imbalance due to wear or corrosion
h. Motor imbalance
i. Base plate loose on foundation or insufficient
strength to support the load
3. Not Enough Pressure
a. Speed too low - Check motor speed
b. Air in liquid
c. Incorrect impeller diameter - Check system
requirements
d. Obstruction in pump or piping
e. Air leaks in suction piping
f. Mechanical defects
7. Pump and/or Motor Noise
a. Pump and motor misalignment
b. Pump cavitation
c. Base plate loose or not grouted
d. Pump bearings worn
e. Motor bearings worn or fan rubs housing
f. Foreign matter in pump
g. Broken shaft
h. Liquid velocity in pump or valves due to greater
liquid flow than anticipated.
i. Pump impeller imbalance due to wear.
4. Pump Works For A While Then Quits
a. Air leaks in suction piping
b. Obstruction in pump or piping
c. Suction lift too high - over 15 feet, chech with
vacuum gauge.
d. Air or gas in liquid
e. Incomplete priming - See Priming
11
FIG. 4060 SERIES END SUCTION
Semi-Open Impeller, Packed Stuffing Box, Grease Lubricated Bearings
ITEM No.
1
2
6
11
*13
*14
*16
17
*18
19
22
*26
*29
*30
32
33
37
*38
40
46
DESCRIPTION
Casing
Impeller
Shaft
Packing Box Cover
Packing
Shaft Sleeve
Bearing (inboard)
Gland, Split
Bearing (outboard)
Frame
Nut, Bearing Lock
Impeller Screw
Lantern Ring
Impeller Washer Gasket
Impeller Key
Bearing Housing - Outboard
Bearing Cover - Outboard
Shaft Sleeve Gasket
Deflector
Coupling Key
ITEM No.
51
69
*73
204
206
207
208
210
211
212
213
216
222
225
236
240
242
243
262
263
DESCRIPTION
Grease Retainer
Lockwasher
Casing Gasket
Adjusting Locknut
Split Gland Clip
Grease Fitting
Pipe Plug
Nut
Set Screw
Cap screw
Cap Screw
Pipe Plug
Drive Cap
Drive Cap
Pipe Plug
Pipe Plug
Grease Fitting
Grease Fitting
Pipe Plug
Pipe Plug
12
ITEM No.
*270
*272
286
DESCRIPTION
Impeller Washer
Impeller Screw O-ring
Jack Screw
(*) Recommended Spare Parts
FIG. 4160 SERIES END SUCTION
Enclosed Impeller, Packed Stuffing Box, Grease Lubricated Bearings
ITEM No.
1
2
6
*7
11
*13
*14
*16
17
*18
19
22
*26
*29
*30
32
33
37
*38
40
46
DESCRIPTION
Casing
Impeller
Shaft
Wear Ring
Packing Box Cover
Packing
Shaft Sleeve
Bearing (inboard)
Gland, Split
Bearing (outboard)
Frame
Nut, Bearing Lock
Impeller Screw
Lantern Ring
Impeller Washer Gasket
Impeller Key
Bearing Housing - Outboard
Bearing Cover - Outboard
Shaft Sleeve Gasket
Deflector
Coupling Key
ITEM No.
51
69
*73
195
204
206
207
208
209
210
211
212
213
216
222
225
236
239
240
242
243
DESCRIPTION
Grease Retainer
Lockwasher
Casing Gasket
Set Screw
Adjusting Locknut
Split Gland Clip
Grease Fitting
Pipe Plug
Machine Bolt
Nut
Set Screw
Cap screw
Cap Screw
Pipe Plug
Drive Cap
Drive Cap
Pipe Plug
Cap Screw
Pipe Plug
Grease Fitting
Grease Fitting
13
ITEM No.
262
263
*270
*272
286
DESCRIPTION
Pipe Plug
Pipe Plug
Impeller Washer
Impeller Screw O-ring
Jack Screw
(*) Recommended Spare Parts
Limited 24 Month Warranty
Crane Pumps & Systems warrants that products of our manufacture will be free of defects in material and workmanship
under normal use and service for twenty-four (24) months after manufacture date, when installed and maintained
in accordance with our instructions.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 factory 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, F.O.B. 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 us, 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. 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) excessive sand or other abrasive material (e) scale or corrosion build-up due to excessive chemical content. Any
modification of the original 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 TRAVEL EXPENSES,
RENTED EQUIPMENT, OUTSIDE CONTRACTOR FEES, UNAUTHORIZED REPAIR SHOP EXPENSES, 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 DAMAGE 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 other person, whether by operation of law or otherwise,
without our prior written approval.
A Crane Co. Company
420 Third Street
Piqua, Ohio 45356
Phone: (937) 778-8947
Fax: (937) 773-7157
www.cranepumps.com
83 West Drive, Brampton
Ontario, Canada L6T 2J6
Phone: (905) 457-6223
Fax: (905) 457-2650
IMPORTANT!
WARRANTY REGISTRATION
Your product is covered by the enclosed Warranty.
To complete the Warranty Registration Form go to:
http://www.cranepumps.com/ProductRegistration/
If you have a claim under the provision of the warranty, contact your local
Crane Pumps & Systems, Inc. Distributor.
RETURNED GOODS
RETURN OF MERCHANDISE REQUIRES A “RETURNED GOODS AUTHORIZATION”.
CONTACT YOUR LOCAL CRANE PUMPS & SYSTEMS, INC. DISTRIBUTOR.
Products Returned Must Be Cleaned, Sanitized,
Or Decontaminated As Necessary Prior To Shipment,
To Insure That Employees Will Not Be Exposed To Health
Hazards In Handling Said Material. All Applicable Laws
And Regulations Shall Apply.
A Crane Co. Company
START-UP REPORT
General Information
Pump Owner’s Name: __________________________________________________________
Address: ____________________________________________________________________
Location of Installation: _________________________________________________________
Contact Person: __________________________________Phone: _______________________
Purchased From: _____________________________________________________________
Nameplate Data
Pump Model #: ___________________ Serial #:_____________________________________
Part #: __________________________ Impeller Diameter: ____________________________
Voltage: _________ Phase: _____ Ø
Hertz: ____________Horsepower: _______________
Full Load Amps: ___________________ Service Factor Amps: __________________________
Motor Manufacturer: ___________________________________________________________
Controls
Control panel manufacturer: _____________________________________________________
Model/Part number: ____________________________________________________________
Number of pumps operated by control panel: ________________________________________
Short circuit protection? YES___ NO___
Type: _________________________________
Number and size of short circuit device(s): ___________ Amp rating: ___________________
Overload Type: _____________ Size: ______________ Amp rating: ___________________
Do protection devices comply with pump and motor Amp rating? YES___ NO___
Are all electrical and panel entry connections tight? YES___ NO___
Is the interior of the panel dry? YES___ NO___
Liquid level Control Brand and Model:______________________________________________
Pre-Startup
All Pumps
Type of equipment: NEW___ REBUILT___ USED___
Condition of equipment at Start-Up: DRY___ WET___ MUDDY___
Was Equipment Stored? YES___ NO___
Length of Storage: ______________________
Liquid being pumped: __________________ Liquid Temperature: _____________________
Supply Voltage/Phase/Frequency matches nameplate? YES___ NO___
Shaft turns freely? YES___ NO___
Direction of rotation verified for 3Ø motors? YES___ NO___
Debris in piping or wet well? YES___ NO___
Debris removed in your presence? YES___ NO___
Pump case/wet well filled with liquid before startup? YES___ NO___
Is piping properly supported? YES___ NO___
Non-Submersible Pumps
Is base plate properly installed / grouted? YES___ NO___ N/A___
Coupling Alignment Verified per I&O Manual? YES___ NO___ N/A___
Grease Cup/Oil Reservoir Level checked? YES___ NO___ N/A___
Submersible Pumps
Resistance of cable and pump motor (measured at pump control):
Red-Black:_______Ohms(Ω)
Red-White:_______Ohms(Ω) White-Black:_______Ohms(Ω)
Resistance of Ground Circuit between Control Panel and outside of pump:__________Ohms(Ω)
MEG Ohms check of insulation:
Red to Ground: _________ White to Ground: __________ Black to Ground: ____________
Operational Checks
Is there noise or vibration present? YES___ NO___ Source of noise/vibration: ___________
Does check valve operate properly? YES___ NO___ N/A___
Is system free of leaks? YES___ NO___
Leaks at: ______________________________
Does system appear to operate at design flow rate? YES___ NO___
Nominal Voltage: _____________________ Phase: 1Ø 3Ø (select one)
Voltage Reading at panel connection, Pump OFF: L1, L2 _____ L2, L3 ____ L1, L3 _____
Voltage Reading at panel connection, Pump ON: L1, L2 ______ L2, L3 ____ L1, L3 _____
Amperage Draw, Pump ON: L1 ____________
L2 _____________
L3 _____________
Submersible Pumps
Are BAF and guide rails level / plumb? YES___ NO___
Is pump seated on discharge properly? YES___ NO___
Are level controls installed away from turbulence? YES___ NO___
Is level control operating properly? YES___ NO___
Is pump fully submerged during operation? YES___ NO___
Follow up/Corrective Action Required
YES___
NO___
Additional Comments:
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Startup performed by: _____________________
Date: ______________________________
Present at Start-Up
( ) Engineer: ____________________________
( ) Operator: ________________________
( ) Contactor:____________________________
( ) Other: ___________________________
All parties should retain a copy of this report for future trouble shooting/reference
A Crane Co. Company
420 Third Street
Piqua, Ohio 45356
Phone: (937) 778-8947
Fax: (937) 773-7157
www.cranepumps.com
83 West Drive, Brampton
Ontario, Canada L6T 2J6
Phone: (905) 457-6223
Fax: (905) 457-2650
Notes

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