Blue Seal | G504 | Operating instructions | Blue Seal G504 Operating instructions

MODELS: G 502 T, G 504 T
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
EMAIL: 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” MOTOR 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 BUILT-IN LEVEL CONTROLS
FOR AUTOMATIC STARTING AND STOPPING. IT IS HOWEVER 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
PANELS WHICH ARE AVAILABLE FROM US INCORPORATING ALL REQUIRED PROTECTION
DEVICES.
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.
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”. THE MAXIMUM SPECIFIC GRAVITY OF
THE PUMPED FLUID SHOULD NOT EXCEED 1.1.
OVERALL DIMENSIONS AND WEIGHT.
G 502T & G 504T
OVERALL HEIGHT
23”(APPROX.)
MAX. DIAMETER
10.75”
MAX. WEIGHT(EXCL. CABLE)
110 lbs.
MAINTENANCE SERVICES REQUIRED.
THE FOLLOWING CHECKS TO BE DONE AT INTERVALS INDICATED BELOW:
1. CONDITION OF SEALS TO BE CHECKED AT EVERY 2500
ASCERTAINING THE CONDITION OF OIL IN THE SEAL CHAMBER.
HRS.
OF
OPERATION
BY
2. MONTHLY RUNNING OF PUMP FOR AT LEAST 5/10 MINUTES AND CHECKING OF AMPERES
DRAWN AND INSULATION RESISTANCE.(MIN. INSULATION RESISTANCE 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 HOSE 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 SPACE TO BE PUMPED BY USING A LIFTING
ROPE ATTACHED TO THE HANDLE/EYEBOLT PROVIDED IN THE PUMP.
7. AT THE
DIRECTION
DIRECTION
PHASES IN
STARTING MOMENT THE PUMP SHALL MAKE A KICK WHICH IS OPPOSITE TO THE
OF ROTATION OF THE IMPELLER. ENSURE THE KICK IS IN THE CORRECT
(SEE THE ARROW CAST ON THE CONTACTOR COVER OF THE PUMP).SHIFT ANY TWO
THE MALE PLUG 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. 30 MINUTES).
9. THE MAXIMUM PUMP SUBMERGENCE RECOMMENDED IS 50 FEET.
10. THE SPECIFIC GRAVITY OF PUMPED FLUID SHOULD NOT EXCEED 1.1 UNDER ANY
CIRCUMSTANCES. PUMP IS DESIGNED TO OPERATE IN FLUIDS WITH pH from 5 – 8.
11. 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.
MAINS VOLTAGE AT SITE
HRC FUSE RECOMMENDED
220 VOLTS / 3 PHASE
380 VOLTS / 3 PHASE
460 VOLTS / 3 PHASE
20 AMPERES
16 AMPERES
15 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.
6.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
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.
TECHNICAL DESCRIPTION.
THE MODY SUBMERSIBLE PUMP IS IN ITSELF A COMPLETE PUMPING STATION. BESIDES A
POWER SUPPLY AND A DISCHARGE HOSE NO EXTRA EQUIPMENT IS REQUIRED. THE
COMPLETE PUMPSET IS IN A MODULAR CONSTRUCTION ENSURING GOOD AND SIMPLE
SERVICEABILITY. THE MAJOR DESIGN FEATURES ARE AS UNDER:
THE MOTOR
A RUGGED ALUMINUM DIE CAST/COPPER
ROTOR
DYNAMICALLY BALANCED TO GRADE 2.5
ACCURACY OF ISO 942.A STAINLESS STEEL SHAFT RUNNING IN TWO BALL BEARINGS.
INSULATION CLASS "F" (155 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. DUAL 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.
SINGLE ROW DEEP GROOVE BALL BEARINGS SEALED FOR LIFE WITH A SPECIAL HIGH
TEMPERATURE BEARING GREASE REQUIRING NO PERIODIC MAINTENANCE WHATSOEVER.
THE HYDRAULIC ELEMENTS.
THE 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 INTERNATIONAL STANDARDS. 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 CONTACTOR 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 THIS 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.(INSPECTION ONCE IN A YEAR IS ENOUGH.)
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. ALWAYS REPLACE COMPLETE NEW BEARING WITH
SPECIAL HIGH TEMPERATURE GREASE.
ELECTRICAL INFORMATION.
MOTORS ARE DESIGNED TO OPERATE ON SINGLE VOLTAGE AND FREQUENCY. MAX. 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. # DW/130/00 SHEETS 1 & 2)
1. ALWAYS REPLACE O-RINGS WITH NEW ONES WHENEVER DISMANTLING AND RE-ASSEMBLING
A PUMP. NEVER RE-USE OLD O-RINGS.
2. REMOVE BASE PLATE(21),STRAINER(20),NUT(18),AND DIFFUSER(19/40).THE DRAWING
SHOWS THESE DETAILS. CHECK BY HAND THAT THE ROTOR SHAFT IS NOT BLOCKED.
3. PLACE THE PUMP ON THE BOTTOM STUDS(17).TAP THE OUTER CASING(10) WITH NYLON
TIPPED HAMMERS TILL IT LOOSENS FROM THE TOP BRACKET(6).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
TIE BOLTS(3) CLEAR OFF THE OUTER CASING.
4. THE SEAL CHAMBER CONTAINS APPROX. 1.5 LITTERS OF OIL. THE LEVEL AND
CONDITION OF THE OIL SHOULD BE CHECKED EVERY SIX MONTHS. UNSCREW THE OIL
PLUGS(66) 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.
5. LAY DOWN THE PUMP AND REMOVE THE REMAINING PARTS.
REMOVE LOCK WASHER(24)(USE IMPELLER SPANNER(T7004)TO
UNSCREWING NUTS) AND SLIDE OFF IMPELLER(26) FROM SHAFT.
SPACERS(27) AND SAND GUARD(59). UNSCREW THE FOUR CHEESE
REMOVE THE SAND GUARD (69) FROM THE SEAL HOUSING (28).
UNSCREW NUTS(23) AND
HOLD IMPELLER WHILE
THEN REMOVE TRIMMING
HEAD SCREWS (72) AND
6. UNSCREW NUTS(18) AND FOUR STUDS(17)AND REMOVE WEAR PLATE(29).THIS CAN BE
EASILY DONE BY INSERTING TWO SCREWDRIVERS BETWEEN WEAR PLATE AND LOWER
BRACKET(15) AND PRYING THE WEAR PLATE LOOSE. ALL THE PUMP PARTS HAVE BEEN
DISMANTLED. REPLACE WORN PARTS.
7. THE OIL DIAPHRAGM(56) IS NOW IN VIEW. UNSCREW BOTH THE OIL PLUGS(66) AND
DRAIN OUT THE OIL FROM THE OIL CHAMBER. LOOSEN SCREWS AND NUTS(33/54) FROM THE
BIG OIL CLAMP(55) AND REMOVE CLAMP. TURN OIL DIAPHRAGM INSIDE OUT AND REMOVE
SMALL OIL CLAMP IN THE SAME FASHION. REMOVE OIL DIAPHRAGM. SLIDE OFF OUTER
RETAINING SPRING(61) FROM ROTOR SHAFT AND REMOVE LOWER MECHANICAL SEAL FROM
ROTOR SHAFT. BE VERY CAREFUL IN HANDLING THE TUNGSTEN CARBIDE SEAL FACE. LEAVE
STATIONARY TUNGSTEN CARBIDE SEAT IN THE SEAL HOUSING(28).UNSCREW FOUR NUTS(65)
AND PULL OUT SEAL HOUSING(28).THE STATIONARY TUNGSTEN 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.
8. REMOVE THE FOUR NOS. DEEP SEATED CAP SCREWS(16) THAT HOLD THE LOWER BEARING
BRACKET AGAINST THE INNER CASING. BY MEANS OF TWO NOS. SCREW DRIVERS REMOVE THE
LOWER BEARING BRACKET FROM THE INNER CASING(12). THE COMPLETE ROTOR(11) WITH
BEARING(68), BEARING COVER AND TUNGSTEN CARBIDE SEAT WILL COME OUT WITH THE
LOWER BEARING BRACKET. REMOVE BOLTS(70) 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 STATIONARY
TC 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).
9. CHECK BOTH UPPER AND LOWER BEARINGS(9 & 68) 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 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 A SPECIAL BEARING WHICH IS PRE-FILLED WITH A
SPECIAL HIGH TEMPERATURE GREASE WHICH ARE AVAILABLE FROM US READILY).
THE TOP BRACKET(6) IS HELD IN POSITION BY FOUR BOLTS(4) ON THE INNER CASING.
UNSCREW THE BOLTS AND REMOVE THE INNER CASING WITH THE HELP OF PULLER FOR
STATOR(T8003).ALTERNATIVELY TWO SCREW DRIVERS MAY BE USED TO PRY THE TOP
BRACKET FROM THE STATOR.
10. THE STATOR IS SHRINK-FITTED IN THE INNER CASING AND IS SUPPLIED WITH THE
O-RINGS(14) AS ONE UNIT. 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 GUIDED
THROUGH THE FOUR BOLTS(4).
2. SLIDE BEARING COVER(13) ON ROTOR SHAFT.
3. 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
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).
4. SLIDE LOWER BEARING BRACKET(15) ON TO LOWER BEARING AND ALIGN FOUR NOS.
HOLES ON BEARING COVER WITH THE TAPPED HOLES ON LOWER BEARING BRACKET. FIT THE
BOLTS(70) AND TIGHTEN BEARING COVER.
5. FIT COMPLETE ROTOR ASSEMBLY IN STATOR HOUSING GUIDING UPPER BEARING IN TOP
BRACKET BEARING SEAT. TIGHTEN FOUR CAP SCREWS(16). 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(T9006) 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 RETAINER SPRING(61) AND FIT IN GROOVE
ON SHAFT.
6. PRESS HOME BY HAND LOWER SEAL TUNGSTEN CARBIDE SEAT INTO SEAL HOUSING(28).
LIGHTLY OIL RUBBER SEAT CUP BEFORE PRESSING IN CAVITY. THE SEAT MUST SIT SQUARE
IN THE HOUSING.
7. FIT SEAL HOUSING(28) INTO LOWER BRACKET AND TIGHTEN NUTS(65).
8. 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 RETAINER SPRING AS FOR THE UPPER SEAL
ASSEMBLY
9. PRESS SAND GUARD(59) INTO SEAL HOUSING(USE A HAND PRESS OR USE A NYLON
HAMMER)
10. TURN OIL BAG INSIDE OUT AND FIT OIL BAG "VEE" SECTION INTO GROOVE IN SEAL
HOUSING(28).USING SMALL OIL BAG CLAMPS AND SCREWS & NUTS CLAMP THE OIL BAG TO
THE SEAL HOLDER. TURN OIL BAG TO CLAMP THE LARGER SIDE "VEE" SECTION TO THE
GROOVE IN THE LOWER BEARING BRACKET IN THE SAME WAY.
11. 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.(A SMALL AMOUNT OF AIR IN THE
OIL BAG WILL NOT BE DETRIMENTAL IN ANY WAY).REPLACE PLUG WITH "O" RING.
12. SLIDE ON WEAR PLATE AGAINST LOWER BEARING BRACKET AND TIGHTEN THE SAME. FIT
KEY(25) ON THE SHAFT AND SLIDE ON IMPELLER. CLEARANCES BETWEEN IMPELLER AND
WEAR PLATE CAN BE ADJUSTED BY MEANS OF THE TRIMMING SPACERS(27).TIGHTEN NUT(23)
AND SEE THAT ROTOR SHAFT IS FREE.
13. FIT OUTER CASING ON TOP BRACKET WITH "O" RING. FIT DIFFUSER AND ADJUST
CLEARANCES. SLIDE ON DIFFUSER WASHERS(22) AND FIT DIFFUSER (19) AGAINST THE
OUTER CASING(10). TIGHTEN BY MEANS OF NUTS(18). FIX STRAINER, BASE PLATE AND
TIGHTEN NUTS(18)
OIL SPECIFICATIONS
A) H.P. ENKLO OIL 46/48
B) SHELL TELLUS 29.
C) CHEVRON UNIVOLT 60/N61
PARTS CATALOG
1. COMPONENTS LIST : AS PER DRAWING NO. DW/130/00 (SHEET 1 & 2).
DRAWINGS :
1. SECTIONAL ASSEMBLY(DW/130/00)(SHEET 1)
2. SEALING ARRANGEMENT WITH MATERIAL PARTS LIST (DW/130/00)(SHEET 2)
R: RECOMMENDED SPARES FOR TWO YEARS OPERATION
SR.NO
DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
MECHANICAL SEAL
MECHANICAL SEAL
"O" RING SET
CABLE GROMMET
CABLE LEAD GROMMET
UPPER BEARING
LOWER BEARING
STRAINER
IMPELLER(G 502T, 60Hz)
IMPELLER(G 504T, 60Hz)
DIFFUSER(G 502T)
DIFFUSER(G 504T)
WEAR PLATE
LOCK WASHER
PART NO.
535-022-00
535-022-00
375-003-66
260-013-66
260-014-66
020-005-07
020-011-07
640-012-11
300-033-22
300-031-22
175-017-80
175-016-80
715-004-80
695-004-21
RECOMMENDED QTY.
1
1
2
2
2
1
1
1
1
1
1
1
1
2
NO.
NO.
SETS.
NOS.
NOS.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NOS.
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
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