Installation and Service Instructions

HD Series Pumps

Version 1.8

Excellence at work. Excellence in life.

Table of Contents

Introduction

General Description

Pumping Principle

HD Models

HD Process Pump Numbering System

Temperature Limits of HD Process Pump Materials

Installation

Packing Adjustment

Lubrication Requirements

Lubrication Instructions for Tuthill Process Pumps

70A, 120A, and 330 Pumps Isometric Drawing

(Models Starting w/ O5 & Packing)

General Parts List for 70A, 120A, and 330 Pumps

70A, 120A, and 330 Pumps Isometric Drawing

(Models Starting w/ O5 & Tuffseals)

General Parts List for 70A, 120A, and 330 Pumps

70A, 120A, and 330 Pumps Isometric Drawings

(Models Starting w/ O5 & Mech. Seals)

General Parts List for 70A, 120A, and 330 Pumps

Disassembly & Reassembly for 70A, 120A, & 330 Pumps

16

14

15

12

13

Fluid Chamber Check Points

Major Disassembly Instructions

Reassembly

Chamber Clearances

600 Pumps Isometric Drawing with Packing

(Models Starting w/ O5)

General Parts List for Model 600 Pumps

600 Pumps Isometric Drawing

(Models Starting w/ O5 & Tuffseals)

19

21

16

19

24

22

23

10

11

7

8

5

6

8

8

3

4

3

3

Version 1.8

General Parts List for Model 600 Pumps

600 Pumps (Models Starting w/ O5 & Mech. Seals)

General Parts List for Model 600 Pumps

Disassembly & Reassembly for Model 600 Pumps

Fluid Chamber Check Points

Reassemble In Accordance With Minor Reassembly

Major Disassembly Instructions

Reassembly

Chamber Clearances

Packings

Torque For Shaft Locknuts

Torque For Faceplate Bolts

Common Causes of Pump Problems

Troubleshooting

Material Returns

Warranty

Contact Information

25

35

35

32

33

36

37

31

31

29

30

26

27

28

38

38

38

Page 2 of 39

Introduction

The HD Series pumps have been certified to the requirements of the ATEX Directive 94/9/EC for use in Category II, Group 2 G applications.

Read this manual before operating or working on the HD Series pumps. If additional information is required to facilitate operation or maintenance, contact the authorized Tuthill distributor shown at the back of this service manual.

HD Series pumps have been designed and manufactured to provide years of service under normal operating conditions. Illustrations used in this manual are for reference purposes only. Consult the factory or an authorized Tuthill distributor for proper part identification.

When ordering replacement parts, provide as much detail as possible to ensure correct parts are provided. Details should include the full model number (typically 12-13 digits but can be 18 digits), serial number, name of part, part number (if known), and part material.

Service Manual # 71 for the HD Series pumps is available at www.tuthillpump.com. The materials furnished for each pump are selected to suit individual applications.

WARNING

Failure to follow these instructions could result in serious bodily injury or death. Do not attempt to work on any Tuthill pump installation before completing the steps below. Disconnect the drive so that it cannot be started while work is being performed. Review the Material

Safety Data Sheet (MSDS) applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling. Vent all pressure within the pump through the suction or discharge lines.

All Tuthill pumps contain residual hydraulic oil from the factory production test. Determine if this is compatible with the fluid you are pumping. If the fluid is incompatible, then the pump must be fully flushed prior to use. If the pump is to be operated at elevated temperatures, the pump should be brought up to operating temperatures gradually. Rapid or sudden introduction of liquids at elevated temperatures into the cold liquid chamber of the pump could cause damage to pump externals, seals or other internal parts.

Pumps can run dry provided provisions are made for the mechanical seal if one is used. Failure to comply with this could cause severe damage to the mechanical seal parts. Pump needs to be earthed separately to avoid a buildup of electro-static charge.

General Description

The design of the Tuthill Industrial Series incorporates externally timed impellers that are supported in the fluid chamber by double row, ball bearings located out of the product stream. This design enables the industrial Series to handle highly viscous abrasive slurries, corrosive acids or suspended solids without degradation, aeration or contamination of the product.

Pumping Principle

Here is How it Works

Rotating impellers develop a vacuum at inlet, drawing material into the cavity…positive action of the impellers displaces material, forcing discharge at pump outlet. Ports are always open; sealing action between impellers and housing prevents fluid flow return.

Version 1.8

Page 3 of 39

HD Models

Material of

Construction

Size

30A

30A

2A

3A

70A

2A

3A

70A

120A

330

600

120A

330

600

450

450

450

450

450

450

450

450

450

450

450

450

450

Max

Speed

450

Max. Capacity

USGPM LPM

24.7

93

135

337

666

24.7

67.5

135

67.5

67.5

135

67.5

135

337

666

93

256

511

256

256

511

256

511

1276

2523

511

1276

2523

150

150

150

450

150

150

450

450

450

450

450

450

450

Max. Pressure Weight

PSI BAR LB

150 10.3

100

KG

45

10.3

10.3

10.3

27.5

10.3

10.3

27.5

27.5

27.5

27.5

27.5

27.5

27.5

100

250

270

280

250

270

280

300

550

900

300

550

900

45

113

122

127

113

122

127

136

249

408

136

249

408

Port Size

(Internal NPT)

1-1/2” Top 1-1/2”

Front

2” Top 2” Front

3” Top 3” Front

3” Top 2” Front

4” Top 3” Front

5” Top 4” Front

6” Right 6” Left

Same As Above

Same As Above

Same As Above

Same As Above

Same As Above

Same As Above

Same As Above

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Page 4 of 39

HD Process Pump Numbering System

1 2 3 4 5 6 7 8 9 10 11 12 13

DIGITS 1 & 2

O1-INDUSTRIAL DUTY

(ID)

O5 – INDUSTRIAL DUTY

(ID) Only Models with

**

O2-STANDARD DUTY

(SD) Ductile Iron Only

DIGITS 3 & 4

05 – Model 30

14 – Model 2A

16 – Model 70A**

29 – Model 3A

31 – Model 120A**

75 – Model 330**

91 – Model 600**

01 – Model 5A

02 – Model 10

03 – Model 16

05 – Model 25A

14 – Model 65

26 – Model 125A

DIGITS 5 & 6

DIGIT 7

DIGIT 8

04 – 316 Stainless Steel (O1, O4 & O5 Models)

09 – Ductile Iron (O1, O2 & O5 Models)

0 – Internal NPT (Std. on ID models)

1 – External NPT (Standard on SD models)

0 – No Relief Valve

1 – Relief Valve (Available on all SD models & ID models 30, 2A, 3A, 70A, 120A)

01 – Hot Clearance

DIGITS 9 & 10

02 – Special Shaft Material

05 – Special Packing

06 – Special Packing Configuration

08 – Mechanical Seals

09 – Special Bushings

10 – Special Clearances

13 – Steam Jacket/Tracing

19 – Special Ports (Flanged, etc.)

21 – Tutriding

26 – Interference Fit Gears

27 – Special U-Cup/Lip Seals

DIGITS 11 & 12

28 - Miscellaneous

01, 02, Etc. (Serialized at the factory)

DIGIT 13 (If Required) D – Double Lobe (Available on ID models only)

T – PTFE housing and faceplate bushings (SD Models)

O4-STANDARD DUTY

(SD) Stainless Steel Only

Version 1.8

Page 5 of 39

Temperature Limits of HD Process Pump Materials

600 °F

200 °F

150 °F

100 °F

50 °F

0 °F

-40 °F

400 °F

350 °F

300 °F

250 °F

550 °F

525 °F

500 °F

450 °F

Note: Viton and PTFE oil seals can be used in place of standard oil seals upon request. PTFE and Gore-Tex gaskets can be used in place of standard seals upon request.

Version 1.8

Page 6 of 39

WARNING

Failure to follow these instructions could result in serious bodily injury or death. Do not attempt to work on any Tuthill pump installation before completing the steps below. Disconnect the drive so that it cannot be started while work is being performed. Review the Material

Safety Data Sheet (MSDS) applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling. Vent all pressure within the pump through the suction or discharge lines. All Tuthill pumps contain residual hydraulic oil from the factory production test. Determine if this is compatible with the fluid you are pumping. If the fluid is incompatible, then the pump must be fully flushed prior to use. If the pump is to be operated at elevated temperatures, the pump should be brought up to operating temperatures gradually. Rapid or sudden introduction of liquids at elevated temperatures into the cold liquid chamber of the pump could cause damage to pump externals, seals or other internal parts. Pumps can run dry provided provisions are made for the mechanical seal if one is used. Failure to comply with this could cause severe damage to the mechanical seal parts. Pump needs to be earthed separately to avoid a buildup of electro-static charge.

Installation

For optimum pump performance the suction line must be at least as large as the corresponding pump port. It should be as short as possible in order to avoid excessive pressure drops and must be airtight. Locate the pump as close to the source of supply as conditions permit, and if possible, below the level of the liquid in the reservoir. When necessary to locate the pump in a pit, provisions should be made to safeguard against flooding. When handling high viscosity liquids, the speed of the pump must be reduced and the size of the inlet lines increased to prevent cavitation. Refer to the NPSHr data for the pump.

Pumps should be filled with liquid at installation. The placement of a strainer on the suction side of the pump will restrict any solids or abrasives from entering the pump, which could cause internal damage. Under no conditions should the pump be used to support external piping loads (weight or expansion). Piping and other equipment should be independently supported. Piping strain can result in misalignment, hot bearings, worn couplings, vibration, etc. It is important that the piping used be clean and free of chips and scales.

The discharge line must be designed with the maximum pressure rating of the pump in mind. Excessive pressure could cause damage to your motor and/or pump. If a pressure relief valve has not been supplied with the pump, some other means of pressure protection must be utilized. This could include in-line safety valves, pressure shutdown switches or other similar devices. Pumps are positive displacement pumps and must be used in conjunction with a pressure relief mechanism.

Every pump installation should have a good foundation. Its structure should be sufficiently strong to hold the pump rigid and to absorb any strain or shock that may be encountered. The installation should be leveled, checked for proper piping alignment, and then fastened securely.

The alignment should be rechecked after the pump’s temperature has reached its operating temperature. Direct drive through a traditional flexible coupling is recommended. However, do not expect the coupling to compensate for misalignment. Contact the coupling manufacturer to determine the maximum amount of misalignment that the coupling can be subjected to. Never operate the pumps without all the guards in place.

Direction of Flow

Tuthill Industrial Process Pumps may be operated in either direction. The direction of flow is dependent on the direction of rotation of the pump drive shaft. When facing the drive shaft of the pump, a clockwise rotation provides a top suction port and a bottom discharge port. This applies to Model 30A, 2A, 3A, 70A, 120A, 330 Pumps (Pages 10, 12 & 14).

Model 600 Pumps are equipped with a vertical shaft arrangement (Page 22, 24, & 26). On these models a clockwise drive shaft rotation will provide a left hand suction port and a right hand discharge port. Flow would be from left to right when facing the drive shaft.

Version 1.8

Page 7 of 39

Packing Adjustment

WARNING

Packing is designed to leak. Therefore, when pumping hazardous liquids, a mechanical seal is recommended to minimize any potential source of leakage that could result in a hazardous condition.

All packings must leak to perform properly. Their purpose is to control leakage—not to prevent it. The slight leakage along the shaft provides proper lubrication to the packing. Pump packings have a lubricant, which acts as a primary sealant for the start-up and breakin phases, during which this lubricant acts to reduce friction. Once the pump is on the line, external lubrication must be supplied to the packing to keep it running properly and to attain longer life. If external lubrication is not supplied, the lubrication in the packings will bleed out due to heat generation. Heat is a primary cause of packing failure. Pumps with packing will require periodic adjustment. To accomplish this, gently and evenly tighten the packing gland nuts, which will further compress the packing. Do not over-tighten. Packing is designed to keep leakage to a slight weep. Normally 2-3 drops per minute is acceptable. If excessive leakage persists after complete adjustment, consider re-packing the stuffing box or using another packing type.

Lubrication Requirements

• Faceplate Bearings- The faceplate bearings are greased. Grease should be added to faceplate bearings when oil is changed.

Add grease through fitting until new grease can be seen exiting under lip seal where shaft enters bearing. Bearings are designed to provide a minimum L10 life of 15,000 hours at maximum speed and pressures conditions.

• Housing Bushing- Housing bushings are fully lubricated by the pumped fluid and are maintenance free.

• Gear Case Bearings- Bearings are designed to provide a minimum L10 life of 15,000 hours at maximum speed and pressures conditions and are splashed lubricated.

Lubrication Instructions for Tuthill Process Pumps

The oil in the gear case of the process pumps is “Lubriplate” APG9 a trade name of Fiske Brothers Refining Company – Toledo, Ohio.

Oil specifications are as follow

Viscosity at 100°F: 816 SSU

API Gravity: 26.5

Fire Point: 440°F

Any 90-weight gear oil may be substituted if equivalent to above

Viscosity at 212°F: 86 SSU

Flash Point: 39°F

Extreme Pressure Additives

The grease used in the faceplate ball bearing of the Industrial Series pump is “Lubriplate” 1200-2

Grease specifications are as follows

Lithium Base

Work Penetration: 280

Minimum Oil Viscosity at 100°F: 950SSU

Any #2 bearing grease may be substituted if equivalent to above

N.L.G.I. #2

A.S.T.M. Dropping Point: 450°F

Water resistant with rust and corrosion inhibitors added

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Page 8 of 39

The following charts on lubrication requirements are offered as a guide only. Common sense approach to preventative maintenance must be exercised for best pump service life. Ambient conditions (temperature, humidity, dust, etc.) can alter schedule.

Model No.

30A

2A & 3A

70A & 120A

330

Gearcase

Capacity - CC

500

1900

250

1000

First Oil Change – Hrs.

500

500

500

500

Subsequent Change – Hrs.

3000

3000

3000

3000

600 1250 500 3000

Above standard lubricants are adequate for operating temperatures between –100°F and +350°F

Total Grease Capacity

Per Pump - CC

30

35

165

140

100

If temperature exceeds 350°F, use the following.

• Oil Specification: Lubriplate APG 250 or equal

• Bearing Grease: 930-AA or equal

Inspection and Repair

Should it be necessary to remove the pump from service for periodic inspection of components and/or a major repair, the following steps should be taken. See following pages for exploded pump views and instructions.

WARNING

Failure to follow these instructions could result in serious bodily injury or death. Do not attempt to work on any Tuthill pump installation before completing the steps below. Only authorized personnel who are familiar with the repair of mechanical products should perform the necessary repair work. You must familiarize yourself with the entire contents of this manual prior to performing any work.

Disconnect the drive so that it cannot be started while work is being performed.

Review the Material Safety Data Sheet (MSDS) applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling.

Vent all pressure within the pump through the suction or discharge lines. Ensure that the pump has cooled to a safe temperature prior to performing any work on the pump.

Version 1.8

Page 9 of 39

General Parts List for 70A, 120A, and 330 Pumps

9

10

11

18

19

20

21

14

15

12

13

16

17

Item #

1

2

3

4

5

6

7

8

(Armco 17-4PH)

Set Screw (CI)

Set Screw (SS)

Hex Head Bolt

Grease Fitting

Bearing Cover

Lock Nut

Lock Washer

Ball Bearing

Lip Seal

Bearing Carrier

Set Screw

Shim --------.002”

Shim --------.005”

Shim --------.015”

Description

Dowel Pin

Cap Screw

Square Key

Timing Gears

Driven Shaft

(Armco 17-4PH)

Gear Key

Cap Screw

Impeller Key (CI)

Impeller Key (SS)

Impellers (CI) S.L.

Impellers (CI) D.L.

Impellers (SS) S.L.

Impellers (SS) D.L.

Drive Shaft

2

*

2

2

2

*

As Req.

2

2

6

2

2

2

As Req.

As Req.

Qty

4

2

1

2

1

2

1

4

Item #

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

42

43

44

39

40

41

Description

Faceplate (CI)

Faceplate (SS)

Hex Head Bolt

Pipe Plug (CI)

Pipe Plug (SS)

V-Ring

Gore-Tex Gasket

Impeller Housing (CI)

Impeller Housing (SS)

Housing Bushings

(CI) DU Bushing

(SS) Carbon Bushing

Packing

Packing Gland (CI)

Split Glands for (SS)

Stud

Nut (CI)

Nut (SS)

Lip Seal

Spacer

Roller Bearing

Cap Screw

Bearing Housing

Pipe Plug (CI)

Pipe Plug (SS)

Gear Case Gasket

Gear Case Cover

Cap Screw

Vented Pipe Plug

Nametag

Drive Screw

Qty

1

*

8

4

1

1

2

4 sets

4

8

8

8

3

2

2

2

1

2

1

1

6

1

1

2

Note: * Exact quantities will vary depending upon actual pump model. (CI) are Cast Iron pumps that will have corresponding steel and/ or ductile iron components. (SS) are Stainless Steel pumps that will have corresponding stainless steel components. Recommended spare parts are in bold text. When ordering spare parts please specify pump model, serial number, part number & part name.

Version 1.8

Page 11 of 39

General Parts List for 70A, 120A, and 330 Pumps

9

10

11

18

19

20

21

14

15

12

13

16

17

Item #

1

2

3

4

5

6

7

8

(Armco 17-4PH)

Set Screw (CI)

Set Screw (SS)

Hex Head Bolt

Grease Fitting

Bearing Cover

Lock Nut

Lock Washer

Ball Bearing

Lip Seal

Bearing Carrier

Set Screw

Shim ---------.002”

Shim ---------.005”

Shim ---------.015”

Description

Dowel Pin

Cap Screw

Square Key

Timing Gears

Driven Shaft

(Armco 17-4PH)

Gear Key

Cap Screw

Impeller Key (CI)

Impeller Key (SS)

Impellers (CI) S.L.

Impellers (CI) D.L.

Impellers (SS) S.L.

Impellers (SS) D.L.

Drive Shaft

2

*

2

2

2

*

As Req.

2

2

6

2

2

2

As Req.

As Req.

Qty

4

2

1

2

1

2

1

4

Item #

22

23

24

25

26

27

28

29

31

32

33

34

35

36

37

38

41

42

43

39

40

44

45

Description

Faceplate (CI)

Faceplate (SS)

Hex Head Bolt

Pipe Plug (CI)

Pipe Plug (SS)

V-Ring

Gore-Tex Gasket

Impeller Housing (CI)

Impeller Housing (SS)

Housing Bushings

(CI) DU Bushing

(SS) Carbon Bushing

Tuffseal

Stud

Nut (CI)

Nut (SS)

Lip Seal

Spacer

Roller Bearing

Cap Screw

Bearing Housing

Pipe Plug (CI)

Pipe Plug (SS)

Gear Case Gasket

Gear Case Cover

Cap Screw

Vented Pipe Plug

Nametag

Drive Screw

Washer

Qty

1

*

8

4

1

1

2

4

8

8

3

2

2

2

1

2

6

1

1

1

1

2

8

Note: * Exact quantities will vary depending upon actual pump model. (CI) are Cast Iron pumps that will have corresponding steel and/ or ductile iron components. (SS) are Stainless Steel pumps that will have corresponding stainless steel components. Recommended spare parts are in bold text. When ordering spare parts please specify pump model, serial number, part number & part name.

Version 1.8

Page 13 of 39

18

19

20

21

14

15

12

13

16

17

General Parts List for 70A, 120A, and 330 Pumps

Item #

1

2

3

4

5

6

7

8

9

10

11

22

(Armco 17-4PH)

Set Screw (CI)

Set Screw (SS)

Hex Head Bolt

Grease Fitting

Bearing Cover

Lock Nut

Lock Washer

Ball Bearing

Lip Seal

Bearing Carrier

Set Screw

Shim ----------.002”

Shim ----------.005”

Shim ----------.015”

Faceplate (CI)

Faceplate (SS)

Description

Dowel Pin

Cap Screw

Square Key

Timing Gears

Driven Shaft

(Armco 17-4PH)

Gear Key

Cap Screw

Impeller Key (CI)

Impeller Key (SS)

Impellers (CI) S.L.

Impellers (CI) D.L.

Impellers (SS) S.L.

Impellers (SS) D.L.

Drive Shaft

Qty

4

2

1

2

1

2

1

4

2

*

2

2

2

*

As Req.

2

2

6

2

2

2

As Req.

As Req.

1

Item #

23

24

25

26

27

28

33

34

35

36

37

38

41

42

43

39

40

44

45

29

30

31

32

Nut (SS)

Lip Seal

Spacer

Roller Bearing

Cap Screw

Bearing Housing

Pipe Plug (CI)

Pipe Plug (SS)

Gear Case Gasket

Gear Case Cover

Cap Screw

Vented Pipe Plug

Nametag

Drive Screw

Seal Gland Gasket

Description

Hex Head Bolt

Pipe Plug (CI)

Pipe Plug (SS)

V-Ring

Gore-Tex Gasket

Impeller Housing (CI)

Impeller Housing (SS)

Housing Bushings

(CI) DU Bushing

(SS) Carbon Bushing

Mechanical Seal

Mech. Seal Gland (CI)

Mech. Seal Gland (SS)

Stud

Nut (CI)

3

2

2

2

1

2

6

1

1

1

1

2

4

4

8

8

4

4

4

1

1

Qty

*

8

2

Note: * Exact quantities will vary depending upon actual pump model. (CI) are Cast Iron pumps that will have corresponding steel and/ or ductile iron components. (SS) are Stainless Steel pumps that will have corresponding stainless steel components. Recommended spare parts are in bold text. When ordering spare parts please specify pump model, serial number, part number & part name.

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Page 15 of 39

Disassembly & Reassembly for 70A, 120A, & 330 Pumps

Minor Disassembly for Fluid Chamber Inspection

1. Remove all burrs on drive shaft with a file or emery paper. Also check for any deposit of paint. Special care should be taken around the keyway and beveled corner on the drive shaft. These two areas are normally where burrs occur. Burrs or paint will cause an obstruction in the bushing area.

2. Drain oil from gear case by removing lower drain plug (38). Remove six cap screws (41) on face of gear case cover (40).

3. Remove gear case cover by sliding over shafts.

4. If the timing gears (4) are a slip fit on the shafts. Check that the gears have the correct timing marks before removal. If necessary, mark them again. Remove the gears by loosening the setscrews. There are two in each gear. Then slide gears off drive end of shaft.

If gear keys are sheared a gear puller may be required. NOTE: Mark gears so that in reassembly the gears may be remounted on the shafts from which they were removed. Remove two gear keys.(6)

5. If interference fitted (IF) timing gears (4) are furnished. Check that the gears have the correct timing marks before removal. If necessary, mark them again. IF gears do not have setscrews. First attempt to remove them can be can be made with a standard gear puller. If the gear puller was not successful in removing the gears, heat the gear OD with a torch and use a hydraulic jack to remove the gears.

NOTE: Mark gears so that in reassembly the gears may be remounted on the shafts from which they were removed. Remove two gear keys.(6)

WARNING

Wear heat-resistant gloves when handling hot components.

6. A. If Packing is used (reference assembly on page 10). Remove packing gland nuts (32) and slide packing gland (30) out of the way.

Then remove packing (29) from both seal chambers in the impeller housing. If pump is equipped with mechanical seals, see below for general instructions and refer to the seal instructions that were shipped with the pump. Also, reference Page 34 for additional packing information. B. If Tuffseals are used (reference assembly on page 12). Loosen Tuffseal set screws that lock the cartridge seal’s collar onto the shaft, on the impeller housing side. Also, reference Page 35 for additional Tuffseal information. C. If mechanical seals are used (reference assembly on page 14). Remove pipe plugs (24) from impeller housing stuffing boxes. This allows access to the mechanical seal set screws holding the seal to the shaft. Mark the shaft where the mechanical seal is so that the correct seal working length can be referenced upon re-assembly. Then loosen the mechanical seal set screws. Loosen the mechanical seal gland nuts (32) and allow the mechanical seal gland to be loose on the housing. Thus, when the shafts are pulled out of this area when removing the faceplate assembly the gland will not fall off. Allow it to hang loosely on the studs. Also, reference Page 35 for additional mechanical seal information.

7. Remove hex head bolts (23) on outboard side of faceplate. Make note on which side the drive shaft is located for reassembly.

Remove entire faceplate assembly by sliding away from impeller housing.

CAUTION

Faceplate assembly will be heavy and not balanced. Use proper lifting methods. This assembly includes the impellers and shafts installed in the faceplate. DO NOT DISTURB the bearing carrier (19) on the bearing bridge on the faceplate. These caps hold the adjustment of the clearance of the impellers in relation to the fluid chamber. If further disassembly is required, refer to major disassembly instructions.

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Page 16 of 39

Fluid Chamber Check Points

Procedure No. 1 - Check for twisted shaft

1. Place faceplate group upright in vise.

CAUTION

Use soft jaws to prevent damage to the gasket seal surfaces. Tighten jaws on sides of bearing bridge.

2. Install carbon steel gear keys on an angle. Angle is to hold gears from sliding down on shaft.

3. Slide proper timing gear on drive shaft, revolving shaft to align key with gear keyway, taking precautions that the timing marks are face out and aligned. There are two punch marks appearing on the gear on the drive shaft and one punch mark on the mating tooth on the driven shaft.

4. Turn impellers to the position shown below. If the dimension X is the same as dimension Y, then there is no shaft damage. If there is a variation, then the shaft is twisted or the impeller keys may be sheared. Disassemble in accordance with major disassembly instructions. If the impeller keys are sheared, then install new keys and recheck for twisted shaft.

X Y

Procedure No. 2 - Install new gears

• Place faceplate group in vise and install keys as in Procedure No. 1

• Slide gear on driven shaft, aligning keyway of gear with woodruff key on shaft

• Position impellers as shown in the sketch in Procedure No. 1 with dimension X the same as dimension Y

• Slide timing gear on drive shaft and align keyway in gear with woodruff key in shaft and mesh gears

• Recheck dimension X and dimension Y to be certain that they are the same

• Mark gears as indicated in Procedure No. 1 and slide gears off shafts and follow minor reassembly instructions

Procedure No. 3 - Install new bushings

• Disassemble in accordance with minor disassembly instructions

• Press worn bushing from impeller housing and gear case and press new bushings in impeller housing

• Press bronze bushings in gear case and remove expansion plug in gear case cover

• Press out worn bushings and press new bushings in gear case cover.

CAUTION:

If impeller housing bushing is steel backed PTFE, do not ream

• Check gearcase lip seals and bearings for damage. Replace parts as necessary

Version 1.8

Page 17 of 39

Reassemble in Accordance with Minor Reassembly Instructions

1. Apply grease to gasket seal surface on impeller housing. Then press gasket in place. Grease is used to hold gasket in position

2. A. If Packing is used (reference assembly on page 10). Place packing glands in seal chambers in housing. Also, reference Page 34 for additional packing information. B. If Tuffseals are used (reference assembly on page 12). Make sure the Tuffseal on the impeller housing side is ready to accept the shafts and that the collar set screws are unscrewed enough so that the shafts can slide through the collars easily. Also, reference Page 35 for additional Tuffseal information.

C. If mechanical seals are used (reference assembly on page 14). Make sure the mechanical seal bodies in the impeller housing stuffing boxes are ready to accept the shafts and that the seal set screws are unscrewed enough so that the shafts can slide through the seals easily. Also, reference Page 35 for additional mechanical seal information.

3. After checking for burrs, insert shafts through housing bushing, packing glands/mechanical seals/Tuffseals and gear case bushings.

V-rings should also be installed while inserting the shafts. Be aware that the V-rings need to be slid onto the shafts because of their snug fit.

Note: Insert drive shaft in the same position as when disassembled.

4. Tighten cap screws, which hold the faceplate in place.

5. Install carbon steel gear keys in shaft keyways.

6. Slip proper timing gear on driven shaft.

7. Slip timing gear on the drive shaft, rotating shaft to align key with gear keyway, taking precautions that the timing marks are face out and aligned. There are two punch marks appearing on the gear on the drive shaft and one punch mark on the mating tooth on the driven shaft.

8. Spin the pump drive shaft several times to be certain that there is no interference from incorrect timing.

9. Apply grease to gasket seal surface on gear case. Press gasket in place. The same gasket is used on both impeller housing and gear case.

10. Slide gear case cover over shafts, being certain that drive shaft bore in cover is properly positioned in relation to drive shaft.

CAUTION

Take care in sliding lip of oil seal over drive shaft. If proper care is not taken, the lip will be damaged and oil leakage will result.

11. Tighten six cap screws holding gear case cover in place.

12. A. If Packing is used (reference assembly on page 10). Install new packing in seal chambers and tighten packing gland nuts to finger tightness. If pump is equipped with mechanical seals, install them according to the seal instructions and reference 12c for general instructions. Also, reference Page 34 for additional packing information. B. If Tuffseals are used (reference assembly on page 12).

Use the seal spacers to set the right collar location. After setting the end clearances, tighten the gland nuts and then collar set screws to lock the seal collar onto the shaft. Finally, turn the spacers away from the collar so they will not interfere with it during operation.

Also, reference Page 35 for additional Tuffseal information. C. If mechanical seals are used (reference assembly on page 14).

Position the mechanical seal body axially on the shaft using the previous mark that was made during disassembly. After setting the end clearances, tighten the seal set screws to the shaft. Install the mechanical seal gland back into the impeller housing stuffing box and tighten the gland nuts (32). Re-install the pipe plugs (24). Also, reference Page 35 for additional mechanical seal information.

13. Install the drainpipe plug.

14. Remove oil level plug and fill gear case with lube oil (see lube oil chart, page 8/9) to the oil level hole.

15. Install and tighten fill plug and oil level plug.

16. Spin the assembled pump several times to be certain that there is no interference from incorrect timing. If no interference is apparent, then the pump is ready to be put back in service.

Version 1.8

Page 18 of 39

Major Disassembly Instructions

The first seven steps are the same as in the minor disassembly procedure. The major disassembly involves the disassembly of the faceplate group.

8. Place faceplate group in a vise.

CAUTION

Use soft vise jaws to prevent damage to gasket seal surface.

9. A. If Packing is used (reference assembly on page 10). Remove packing gland nuts (32) and slide packing gland (30) out of the way. Then remove packing (29) from both seal chambers on faceplate. If pump is equipped with mechanical seals, refer to the seal instructions that were shipped with the pump. Also, reference Page 34 for additional packing information. B. If Tuffseals are used (reference assembly on page 12). Loosen Tuffseal set screws that lock the cartridge seal’s collar onto the shaft. Also, reference

Page 35 for additional Tuffseal information.

C. If mechanical seals are used (reference assembly on page 14). Remove pipe plugs

(24) from impeller housing stuffing boxes. This allows access to the mechanical seal set screws holding the seal to the shaft. Mark the shaft where the mechanical seal is so that the correct seal working length can be referenced upon re-assembly. Then loosen the mechanical seal set screws. Loosen the mechanical seal gland nuts (32) and allow the mechanical seal gland to be loose on the housing. Thus, when the shafts are pulled out of this area the gland will not fall off. Allow it to hang loosely on the studs. Also, reference Page 35 for additional mechanical seal information.

10. Remove six bearing hex head bolts (12).

11. Remove the two bearing covers (14).

12. Remove the two faceplate bearing locknuts (15).

13. Slide impeller and shaft assembly out through the fluid chamber side of faceplate.

14. Remove the two ball bearings (17) from the bearing bridge on faceplate.

15. Check condition of lip seals (18) and replace if required.

16. Remove the two setscrews (11) from each impeller hub.

17. Press shafts through impellers by placing impeller and shaft assembly in press with threaded stub shaft up.

18. Remove woodruff impeller keys.

Version 1.8

Page 19 of 39

Reassembly

1. A. Install impellers onto shafts [For non-galling impellers (ductile iron)]. Apply lubricant to shaft end on which impeller fits

(White lead is recommended). Slip impeller on shaft from the threaded stub shaft end. Install stainless steel woodruff impeller key. Align keyway in impeller with woodruff impeller key. Press impeller into proper position, and install setscrews as tight as possible. The dimensions shown below are given from the shoulder on the shaft to the nearest flat face on the hub of the impeller.

B. Install impellers onto shafts [For galling impellers (Stainless Steel)]. Impellers must be shrunk on the shafts, due to galling properties of the material. Heat impellers to 500-550°F for 1/2 - 2 hours. Quickly assemble shaft and impeller with keys in place into proper position according to the dimensions from above. Allow cooling.

CAUTION

Wear heat-resistant gloves when handling hot components.

Pump Size

70A & 120A

Impeller Location (inches)

5.677 – 5.690

330 6.942 – 6.955

2. Install lip seals (18) in faceplate (22), in bottom of bearing bores on bearing bridge (19).

3. Install faceplate bearings (17) in bearing bores. Before installation, pack bearings with grease.

4. A. If Packing is used (reference assembly on page 10). Insert packing (29) and glands (30) in seal chambers on faceplate. Also, reference Page 34 for additional packing information. B. If Tuffseals are used (reference assembly on page 12). Install Tuffseals onto impeller stuffing boxes. Use the gland washers (45) and nuts (32) to hand tighten the seal glands to the stuffing boxes. Do not fully tighten the nuts. Also, reference Page 35 for additional Tuffseal information. C. If mechanical seals are used (reference assembly on page 14). Press in the stationary seal seat into the mechanical seal gland if replacing the seal or re-use the existing one. Have the seal bodies and seal glands nearby as those will have to be slipped onto the shafts as one is assembling the shafts through the impeller faceplate. Loosen the pipe plugs (24) so one will have access to the mechanical seal set screws in order to set the correct working height of the seal. Also, reference Page 35 for additional mechanical seal information.

5. Insert impeller and shaft assemblies, threaded portion first, through stuffing box, packing/mechanical seal body and seat, Tuffseals, seal gland, and inner race of faceplate bearing. Secure assemblies in this position by tightening the faceplate bearing lock nuts (15).

V-rings (25) should also be installed while inserting the shafts. Be aware that the V-rings need to be slid onto the shafts because of their snug fit.

6. Insert bearing cover (14) in place and tighten bearing hex head bolts (12). The impeller and shaft assemblies are now secure in the faceplate.

7. Check the clearance with a feeler gauge, between the machine face of the faceplate and the flat surface on the lobe of the impeller.

This setting clearance will vary with the material of construction and pumping temperature. See chart below for the proper setting clearance. This clearance is checked by revolving the impeller and shaft 360°, while checking the clearance at multiple positions. All other clearances are automatically set if this clearance is correct.

Version 1.8

Page 20 of 39

Chamber Clearances

Faceplate gaskets compress to approximately .003 - .004 inches when pump bolts are tightened.

For impeller assembly settings and resultant clearances, see below.

MODEL MATERIAL

CLEARANCES

Non-Gall

Gall

Non-Gall

Gall

Standard

Hot

Standard

Hot

Standard

Hot

Standard

Hot

A IMPELLER SETTING

MIN.

(SIDE)

.0020

.0060

.0065

.0105

.0040

.0090

.0105

.0155

MAX.

.0025

.0065

.0070

.0115

.0045

.0100

.0115

.0165

B RESULTING SIDE

CLEARANCE

(OPPOSITE SIDE)

MIN.

MAX.

Models: 70A & 120A

.0025

.0080

.0065

.0070

.0105

.0120

.0125

.0165

Model: 330

.0045

.0100

.0090

.0150

.0105

.0155

.0165

.0215

C ON RADII

MIN.

.0040

.0080

.0080

.0120

.0060

.0110

.0120

.0170

C

MAX.

.0060

.0100

.0100

.0140

.0080

.0130

.0140

.0190

Single Lobe Impeller

D RESULTING PASS

OVER

MIN.

MAX.

.0005

.0035

.0035

.0060

.0015

.0050

.0060

.0100

.0045

.0075

.0075

.0110

.0065

.0110

.0120

.0160

A

A

C

C

C

B B

D D

Housing

FacePlate

Mating Impeller

8. If the impellers are properly set on the shaft to dimensions from step 1, then the initial setting clearance will always be too large.

Thus, to move the impeller to the proper setting, add shims between bottom of bearing bore and the bearing outer race. The following shims are available:

• Red .002”

• Blue .005”

• Pink .015”

9. Grease faceplate bearings thru fittings on bearing caps.

10. For the remaining reassembly procedure, refer to steps 1 - 16 in Minor Reassembly Instructions.

Version 1.8

Page 21 of 39

General Parts List for Model 600 Pumps

Item #

1

2

3

4

5

6

7

19

20

21

22

15

16

17

18

23

24

25

10

11

8

9

12

13

14

Description

Lock Nut

Lock Washer

Driven Shaft

(Armco 17-4PH)

Impeller Key (CI)

Impeller Key (SS)

Set Screw

Impellers (CI) S.L.

Impellers (CI) D.L.

Impellers (SS) S.L.

Impellers (SS) D.L.

Drive Shaft

(Armco 17-4PH)

Gear Key

Key

Lip Seal

Bearing Spacer

Eye Bolt

Roller Bearing

Timing Gear

Dowel Pin

Nametag

Drive Screw

Vented Pipe Plug

Gear Case

Gear Case Gasket

Hex Head Bolt

Gear Case Cover

Pipe Plug

Grease Fitting

Hex Head Bolt

Qty

2

2

1

2

4

2

1

1

1

10

1

2

1

2

1

2

2

16

5

2

2

1

1

2

2

Item #

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

Description

Bearing Cover

Ball Bearing

Set Screw

Bearing Carrier

Nut (CI)

Nut (SS)

Stud

Shim --------------.002”

Shim --------------.005”

Shim --------------.015”

Faceplate (CI)

Faceplate (SS)

Pipe Plug (CI)

Pipe Plug (SS)

Gore-Tex Gasket

Packing

Cap Screw

Dowel Pin

Housing Bushings

DU Bushing (CI)

Carbon Bushing (SS)

Impeller Housing (CI)

Impeller Housing (SS)

Cap Screw

Packing Gland (CI)

Split Glands for (SS)

V-Ring

Qty

2

2

6

2

8

8

As Req.

As Req.

As Req.

1

8

1

4 sets

16

2

2

1

4

4

8

4

Note: (CI) are Cast Iron pumps that will have corresponding steel and/or ductile iron components. (SS) are Stainless Steel pumps that will have corresponding stainless steel components. Recommended spare parts are in bold text. When ordering spare parts please specify pump model, serial number, part number & part name.

Version 1.8

Page 23 of 39

General Parts List for Model 600 Pumps

Item #

1

2

3

4

5

6

7

19

20

21

22

15

16

17

18

23

24

25

10

11

8

9

12

13

14

Description

Lock Nut

Lock Washer

Driven Shaft

(Armco 17-4PH)

Impeller Key (CI)

Impeller Key (SS)

Set Screw

Impellers (CI) S.L.

Impellers (CI) D.L.

Impellers (SS) S.L.

Impellers (SS) D.L.

Drive Shaft

(Armco 17-4PH)

Gear Key

Key

Lip Seal

Bearing Spacer

Eye Bolt

Roller Bearing

Timing Gear

Dowel Pin

Nametag

Drive Screw

Vented Pipe Plug

Gear Case

Gear Case Gasket

Hex Head Bolt

Gear Case Cover

Pipe Plug

Grease Fitting

Hex Head Bolt

Qty

2

2

1

2

4

2

1

1

1

10

1

2

1

2

1

2

2

16

5

2

2

1

1

2

2

Item #

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

Description

Bearing Cover

Ball Bearing

Set Screw

Bearing Carrier

Nut (CI)

Nut (SS)

Stud

Shim ----------------.002”

Shim ----------------.005”

Shim ----------------.015”

Faceplate (CI)

Faceplate (SS)

Pipe Plug (CI)

Pipe Plug (SS)

Gore-Tex Gasket

Tuffseal

Cap Screw

Dowel Pin

Housing Bushings

DU Bushing (CI)

Carbon Bushing (SS)

Impeller Housing (CI)

Impeller Housing (SS)

Cap Screw

V-Ring

Qty

2

2

6

2

8

8

As Req.

As Req.

As Req.

1

8

1

4

16

2

2

1

4

4

Note: (CI) are Cast Iron pumps that will have corresponding steel and/or ductile iron components. (SS) are Stainless Steel pumps that will have corresponding stainless steel components. Recommended spare parts are in bold text. When ordering spare parts please specify pump model, serial number, part number & part name.

Version 1.8

Page 25 of 39

General Parts List for Model 600 Pumps

Item #

1

2

3

4

5

6

7

19

20

21

22

15

16

17

18

23

24

25

10

11

8

9

12

13

14

Description

Lock Nut

Lock Washer

Driven Shaft

(Armco 17-4PH)

Impeller Key (CI)

Impeller Key (SS)

Set Screw

Impellers (CI) S.L.

(CI) D.L.

(SS) S.L.

(SS) D.L.

Drive Shaft

(Armco 17-4PH)

Gear Key

Key

Lip Seal

Bearing Spacer

Eye Bolt

Roller Bearing

Timing Gear

Dowel Pin

Nametag

Drive Screw

Vented Pipe Plug

Gear Case

Gear Case Gasket

Hex Head Bolt

Gear Case Cover

Pipe Plug

Grease Fitting

Hex Head Bolt

Qty

2

2

1

2

4

2

1

1

1

10

1

2

1

2

1

2

2

16

5

2

2

1

1

2

2

Item #

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

Description

Bearing Cover

Ball Bearing

Set Screw

Bearing Carrier

Nut (CI)

Nut (SS)

Stud

Shim ----------------.002”

Shim ----------------.005”

Shim ----------------.015”

Faceplate (CI)

Faceplate (SS)

Pipe Plug (CI)

Pipe Plug (SS)

Gore-Tex Gasket

Mechanical Seals

Cap Screw

Dowel Pin

Housing Bushings

(CI) DU Bushing

(SS) Carbon Bushing

Impeller Housing (CI)

Impeller Housing (SS)

Cap Screw

Mech. Seal Gland (CI)

Mech. Seal Gland (SS)

V-Ring

Seal Gland Gasket

Qty

2

2

6

2

8

8

As Req.

As Req.

As Req.

1

8

1

4

16

2

2

1

4

4

4

4

4

Note: (CI) are Cast Iron pumps that will have corresponding steel and/or ductile iron components. (SS) are Stainless Steel pumps that will have corresponding stainless steel components. Recommended spare parts are in bold text. When ordering spare parts please specify pump model, serial number, part number & part name.

Version 1.8

Page 27 of 39

WARNING

Failure to follow these instructions could result in serious bodily injury or death. Do not attempt to work on any Tuthill pump installation before completing the steps below. Disconnect the drive so that it cannot be started while work is being performed. Review the Material

Safety Data Sheet (MSDS) applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling. Vent all pressure within the pump through the suction or discharge lines. All Tuthill pumps contain residual hydraulic oil from the factory production test. Determine if this is compatible with the fluid you are pumping. If the fluid is incompatible, then the pump must be fully flushed prior to use. If the pump is to be operated at elevated temperatures, the pump should be brought up to operating temperatures gradually. Rapid or sudden introduction of liquids at elevated temperatures into the cold liquid chamber of the pump could cause damage to pump externals, seals or other internal parts. Pumps can run dry provided provisions are made for the mechanical seal if one is used. Failure to comply with this could cause severe damage to the mechanical seal parts. Pump needs to be earthed separately to avoid a buildup of electro-static charge.

Disassembly & Reassembly for Model 600 Pumps

Minor Disassembly For Fluid Chamber Inspection

1. Remove all burrs on drive shaft with a mill file or emery paper. Also check for deposit of paint. Special care should be taken around the keyway and beveled corner on the drive shaft. These two areas are normally where burrs appear. Burrs or paint will cause an obstruction in the bushing area.

2. Drain oil from gear case by removing lower drainpipe plug. Remove cap screws (23) on face of gear case cover.

3. Remove gear case cover (22) by sliding over shafts.

4. If the timing gears (14) are a slip fit on the shafts. Mark gears so that in reassembly the gears may be remounted on the shafts from which they were removed. Remove the gears by loosening the setscrews. There are two in each gear. Then slide gears off drive end of shaft. If gear keys are sheared a gear puller may be required. Remove two woodruff gear keys (8).

5. If interference fitted (IF) timing gears (14) are furnished. Mark gears so that in reassembly the gears may be remounted on the shafts from which they were removed. IF gears do not have setscrews. First attempt to remove them can be can be made with a standard gear puller. Check that the gears have the correct timing marks before removal. If necessary, mark them again. If the gear puller was not successful in removing the gears, heat the gear OD with a torch and use a hydraulic jack to remove the gears.

WARNING

Wear heat-resistant gloves when handling hot components.

6. A. If Packing is used (reference assembly on page 22). Remove packing gland nuts (30) and slide packing gland (42) out of the way.

Then remove packing (36) from both seal chambers in the impeller housing. If pump is equipped with mechanical seals, see below for general instructions and refer to the seal instructions that were shipped with the pump. Also, reference Page 34 for additional packing information.

B. If Tuffseals are used (reference assembly on page 23). Loosen Tuffseal set screws that lock the cartridge seal’s collar onto the shaft, on the impeller housing side. Also, reference Page 35 for additional Tuffseal information. C. If mechanical seals are used (reference assembly on page 25). Remove pipe plugs (34) from impeller housing stuffing boxes. This allows access to the mechanical seal set screws holding the seal to the shaft. Mark the shaft where the mechanical seal is so that the correct seal working length can be referenced upon re-assembly. Then loosen the mechanical seal set screws. Loosen the mechanical seal gland nuts (30) and allow the mechanical seal gland to be loose on the housing. Thus, when the shafts are pulled out of this area when removing the faceplate assembly the gland will not fall off. Allow it to hang loosely on the studs. Also, reference Page 35 for additional mechanical seal information.

7. Remove hex head bolts (25) on outboard side of faceplate. Make note on which side the drive shaft is located for reassembly.

Remove entire faceplate by sliding away from impeller housing.

CAUTION

Faceplate assembly will be heavy and not balanced. Use proper lifting methods. This assembly includes the impellers and shafts installed in the faceplate. Do not disturb the bearing covers (26) on the bearing bridge on the faceplate. These covers hold the adjustment of clearance of the impeller in relation to the fluid chamber. If further disassembly is required, refer to major disassembly instructions.

Version 1.8

Page 28 of 39

Fluid Chamber Check Points

Procedure No. 1 - Check for twisted shaft

1. Place faceplate group upright in vise. Caution: Use soft jaws to prevent damage to the gasket seal surfaces. Tighten jaws on sides of bearing bridge.

2. Install carbon steel gear keys on an angle. Angle is to hold gears from sliding down on shaft.

3. Slide proper timing gear on drive shaft, revolving shaft to align key with gear keyway, taking precautions that the timing marks are face out and aligned. There are two punch marks appearing on the gear on the drive shaft and one punch mark on the mating tooth on the driven shaft.

4. Turn impellers to the position shown below. If the dimension X is the same as dimension Y, then there is no shaft damage. If there is a variation, then the shaft is twisted or the impeller keys may be sheared. Disassemble in accordance with major disassembly instructions. If the impeller keys are sheared, install new keys and recheck for twisted shaft.

X Y

Procedure No. 2 - Install new gears

1. Place faceplate group in vise and install woodruff keys as in Procedure No. 1

2. Slide gear on driven shaft, aligning keyway of gear with woodruff key on shaft

3. Position impellers as shown in the sketch in Procedure No. 1 with dimension X the same as dimension Y

4. Slide timing gear on drive shaft and align keyway in gear with woodruff key in shaft and mesh gears

5. Recheck dimension X and dimension Y to be certain that they are the same

6. Mark gears as indicated in Procedure No. 1

7. Slide gears off shafts and follow minor reassembly instructions

Procedure No. 3 - Install new bushings

1. Disassemble in accordance with minor disassembly instructions.

2. Press worn bushing from impeller housing and gear case.

3. Press new bushings in impeller housing.

4. Press bronze bushings in gear case.

5. Remove expansion plug in gear case cover.

6. Press out worn bushings and press new bushings in gear case cover.

7. Check gear case lip seals and bearings for damage. Replace parts as necessary.

CAUTION

If impeller housing bushing is steel backed PTFE, do not ream.

Version 1.8

Page 29 of 39

Reassemble In Accordance With Minor Reassembly

1. Apply grease to gasket seal surface on impeller housing. Then press impeller-housing gasket in place. Grease is used to hold gasket in position.

2. A. If Packing is used (reference assembly on page 23). Place packing glands (42) in seal chambers of housing (40). Also, reference

Page 34 for additional packing information. B. If Tuffseals are used (reference assembly on page 23). Make sure the TuffSeall on the impeller housing side is ready to accept the shafts and that the collar set screws are unscrewed enough so that the shafts can slide through the collars easily. Also, reference Page 35 for additional Tuffseal information. C. If mechanical seals are used (reference assembly on page 25). Make sure the mechanical seal bodies in the impeller housing stuffing boxes are ready to accept the shafts and that the seal set screws are unscrewed enough so that the shafts can slide through the seals easily. Also, reference Page 35 for additional mechanical seal information.

3. After checking for burrs, insert shafts, through housing bushing, packing glands/mechanical seals/Tuffseals and gear case bushings.

V-rings (43) should also be installed while inserting the shafts. Be aware that the V-rings need to be slid onto the shafts because of their snug fit. Note: Insert drive shaft on same side as when disassembled.

4. Tighten cap screws, which hold faceplate in place.

5. Slip fit timing gears. Install carbon steel gear keys in shaft keyways. Slip proper timing gear on driven shaft. Then slip timing gear on drive shaft, revolving shaft to align woodruff key with gear keyway, taking precautions that the timing marks are face out and aligned.

These marks are two center punch marks on the gear on the drive shaft and one center punch mark on the mating tooth cavity. Then turn pump drive shaft over several times to be certain that there is no interference from being out of time. Tighten setscrews on shaft. Then install locking setscrew.

6. Interference fitted timing gears. Make sure that gears are properly marked with the timing marks and that the bores and keyways are free of burrs. Repair as necessary. Heat the gears to 500°F-550°F in an oven for 40 minutes. Add keys to the drive and driven shafts.

WARNING

Wear heat-resistant gloves when handling hot components.

7. Install the timing gear on the driven shaft first, making sure that the timing marks are facing outward. Assure that the driven gear has cooled before installing the drive gear. Match the timing gears and install the drive gear. Rotate the shafts after the gear cools to assure the correct timing of the impellers.

8. If timing is correct, apply grease to gasket seal surface on gear case. Press gear case gasket in place.

9. Slide gear case cover over shafts, being certain that drive shaft bore in cover is properly positioned in relation to drive shaft. Then tighten cap screws holding gear case cover in place. CAUTION: Take care in slipping lip of oil seal over drive shaft. If proper care is not taken, the lip will be damaged and oil leakage will result.

10. A. If Packing is used (reference assembly on page 23). Install new packing in seal chambers and tighten packing gland nuts to finger tightness. If pump is equipped with mechanical seals, install them according to the seal instructions and reference 12c for general instructions. Also, reference Page 34 for additional packing information. B. If TuffSealls are used (reference assembly on page 23).

Use the seal spacers to set the right collar location. After setting the end clearances, tighten the gland nuts and then collar set screws to lock the seal collar onto the shaft. Finally, turn the spacers away from the collar so they will not interfere with it during operation.

Also, reference Page 35 for additional Tuffseal information. C. If mechanical seals are used (reference assembly on page 25).

Position the mechanical seal body axially on the shaft using the previous mark that was made during disassembly. After setting the end clearances, tighten the seal set screws to the shaft. Install the mechanical seal gland back into the impeller housing stuffing box and tighten the gland nuts (32). Re-install the pipe plugs (24). Also, reference Page 35 for additional mechanical seal information.

11. Install drainpipe plug. Remove oil level plug. Fill gear case with lube oil (see lube chart on page 8&9) until oil comes out oil level hole. Then install and tighten fill plug and oil level plug.

12. Spin the assembled pump several times to be certain that there is no interference from incorrect timing. If no interference is apparent, the pump is ready to be put back in service.

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Major Disassembly Instructions

The first seven steps are the same as in the minor disassembly procedure. The major disassembly involves the disassembly of the faceplate group.

8. Place faceplate group in a vise. CAUTION: Use soft vise jaws to prevent damage to gasket seal surface.

9. A. If Packing is used (reference assembly on page 23). Remove packing gland nuts (30) and slide packing gland (42) out of the way. Then remove packing (36) from both seal chambers on faceplate. If pump is equipped with mechanical seals, refer to the seal instructions that were shipped with the pump. Also, reference Page 34 for additional packing information. B. If TuffSealls are used (reference assembly on page 23). Loosen Tuffseal set screws that lock the cartridge seal’s collar onto the shaft. Also, reference

Page 35 for additional TuffSeall information. C. If mechanical seals are used (reference assembly on page 25). Remove pipe plugs

(34) from impeller housing stuffing boxes. This allows access to the mechanical seal set screws holding the seal to the shaft. Mark the shaft where the mechanical seal is so that the correct seal working length can be referenced upon re-assembly. Then loosen the mechanical seal set screws. Loosen the mechanical seal gland nuts (30) and allow the mechanical seal gland to be loose on the housing. Thus, when the shafts are pulled out of this area the gland will not fall off. Allow it to hang loosely on the studs. Also, reference Page 35 for additional mechanical seal information.

10. Remove six hex head bolts (25). Remove bearing covers (26). Press tines of lock washers (2) out of grooves on lock nut (1).

Remove lock nut.

11. Remove bearing carrier (29) and bearing (27). CAUTION: Note the shims that are placed between bearing carrier (29) and faceplate (33). If shafts and impellers are not replaced, these shims must be returned to the same position from which they were removed. Now slide impeller and shaft assembly out through the fluid chamber side of faceplate.

12. Remove the two double row faceplate ball bearings (27) from the bearing carriers (29). Then remove lip seals (10) and check condition. Replace if required.

13. If the shaft or impeller needs to be replaced, remove two set screws (5) from each impeller hub. Then press shafts through impellers by placing impeller and shaft assembly in press with threaded stub shaft up. Remove impeller keys (4).

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Reassembly

1. A. Install impellers onto shafts [For non-galling impellers (ductile iron)]. Apply lubricant to shaft end on which impeller fits (White lead is recommended). Slip impeller on shaft from the threaded stub shaft end. Install steel woodruff impeller key. Align keyway in impeller with woodruff impeller key. Press impeller into proper position, and install setscrews as tight as possible. The dimensions shown below are given from the shoulder on the shaft to the nearest flat face on the hub of the impeller. B. Install impellers onto shafts [For galling impellers (Stainless Steel)] Impellers must be shrunk on the shafts, due to galling properties of the material. Heat impellers to 500-550°F for 1 ½ -2 hours. Quickly assemble shaft and impeller with keys in place into proper position according to the dimensions from above. Allow cooling.

Pump Size

600

Impeller Location (inches)

8.018 – 8.033

WARNING

Wear heat-resistant gloves when handling hot components.

2. Install lip seals (10) in faceplate (23), in bottom of bearing bores on bearing bridge.

3. Install faceplate bearings (27) in bearing bores. Before installation, pack bearings with grease.

4. A. If Packing is used (reference assembly on page 10). Insert packing (36) and glands (42) in seal chambers on faceplate. Also, reference Page 34 for additional packing information. B. If TuffSealls are used (reference assembly on page 12). Install Tuffseals onto impeller stuffing boxes. Use the gland washers and nuts (30) to hand tighten the seal glands to the stuffing boxes. Do not fully tighten the nuts. Also, reference Page 35 for additional Tuffseal information.

C. If mechanical seals are used (reference assembly on page 14). Press in the stationary seal seat into the mechanical seal gland if replacing the seal or re-use the existing one. Have the seal bodies and seal glands nearby as those will have to be slipped onto the shafts as one is assembling the shafts through the impeller faceplate. Loosen the pipe plugs (34) so one will have access to the mechanical seal set screws in order to set the correct working height of the seal. Also, reference Page 35 for additional mechanical seal information.

5. Insert impeller & shaft assemblies, threaded portion 1st, through stuffing box, packing/mechanical seal, body, seat, Tuffseals, seal gland, and inner race of faceplate bearing. V-rings should also be installed while inserting the shafts. Beware the V-rings (43) need to be slid onto the shafts because their snug fit. Secure assemblies in this position by tightening faceplate & bearing lock nuts (1).

6. Insert bearing covers (26) in place and tighten bearing hex head bolts (25). The impeller and shaft assemblies are now secure in the faceplate.

7. Check the clearance with a feeler gauge, between the machine face of the faceplate and the flat surface on the lobe of the impeller.

This setting clearance will vary with the material of construction and pumping temperature. See chart below for the proper setting clearance. This clearance is checked by revolving the impeller and shaft 360° while checking the clearance at multiple positions. All other clearances are automatically set if this clearance is correct.

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Chamber Clearances

Faceplate gaskets compressed to approximately .003 - .004 inches when pump bolts are tightened. Impeller assembly settings and resultant clearances see below.

MODEL 600

MATERIAL

CLEARANCES

A IMPELLER

SETTING (SIDE)

MIN.

Non-Gall Standard .0060

MAX.

.0065

Gall

Hot

.0120

Standard .0185

Hot

.0245

.0130

.0195

.0255

B RESULTING

SIDE CLEARANCE

(OPPOSITE SIDE)

MIN.

.0065

MAX.

.0120

.0120

.0185

.0245

.0180

.0245

.0305

C ON RADII

MIN.

.0080

.0140

.0200

.0260

MAX.

.0100

.0160

.0220

.0280

D RESULTING

PASS OVER

MIN.

.0035

.0070

.0130

.0170

MAX.

.0085

.0130

.0190

.0230

C

Single Lobe Impeller

A

A

C

C

C

B B

D

D

Housing

FacePlate

Mating Impeller

8. If the impellers are properly set on the shaft to dimensions from step 1, then the initial setting clearance will always be too large.

Thus, to move the impeller to the proper setting, add shims between bottom of bearing bore and the bearing outer race.The following shims are available:

• Red .002”

• Blue .005”

• Pink .015”

9. Grease faceplate bearings thru fittings on bearing caps.

10. For the remaining reassembly procedure, refer to steps 1 - 16 in Minor Reassembly Instructions.

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Packings

Installing Packings in Pumps

1. Remove all old packing using a packing hook. Clean stuffing box and shaft thoroughly and examine shaft for wear or scoring. Check bearings for wear as this can cause an eccentric shaft rotation resulting in excessive leakage. Packings will not act as a bearing. If shaft surface is worn, replace shaft or have seal surface area resurfaced.

2. Be certain the proper size packing is used. The following packing sizes will apply

Pump Model

70A & 120A

330

600

Packing Size

7/16” Square

1/2” Square

1/2” Square

Shaft Diameter

1-7/8”

2-1/4”

2-1/2”

6

6

No. of Rings

6

3. Always cut packings into separate rings. Never coil around shaft. (standard factory packings are pre-cut and pre-formed) If bulk packing is used cut each ring on a mandrel the same size as the pump shaft. Try rings in stuffing box to be certain that each ring fills the seal chamber and that there is no gap between packing joints.

4. Install one ring at a time, seating each ring independently. Use clean oil to lubricate shaft and inside of stuffing box. Joints should be staggered and kept at least 90° apart. Each individual ring should be firmly seated with a tamping tool. Never depend entirely on the gland to seat a set of packings. This practice will jam the last rings installed but leave the front rings loose. The result is excessive and rapid wear.

5. After last ring is installed, tighten gland nuts finger tight. Then start pump and take up nuts until leakage is decreased. Stopping leakage at this point will cause packing to burn. If temperature rises in seal area, back off on packing nuts as this indicates excessive gland pressure.

6. Allow packing to leak freely for at least one hour when starting up a newly packed pump. Take up gland nuts gradually, 1/16 turn every 5-10 minutes, until leakage stabilizes at about 3-5 drops per minute. If temperature in seal area increases, back off and start over.

Note: Replace packing when leakage cannot be controlled by further take-up of gland. Test results indicate that 70% of the wear occurs on the first two rings of packing nearest the gland. Rings next to the gland work the hardest. The rings in the bottom of the stuffing box serve to throttle some fluid pressure. On abrasive service the bottom ring takes most of the beating. Therefore, this ring should be a firm ring.

How to Pack for Abrasive Liquids

As used here “Abrasives” is a broad term intended to cover the problem of packing against slurries, congealing liquids and the likes. They cause the greatest damage to equipment, and present difficulties for packing. In general, this involves flush, purges and temperature control. Hard facing on the shaft seal surfaces, such as stellite or ceramic, are also recommended. When pumping slurries and abrasives an external source of clear or otherwise suitable liquid must be force fed at a pressure higher than that existing in the stuffing box. This differential pressure is in the area of 10-25 psi.

Suspended Solids

Solids which are suspended in liquids and which are an inherent part of their structure would include starch, clay slurry, muddy water and other similar slurries. This is best handled by an external flush of clear liquid through a lantern ring as shown. This arrangement will result in a small amount of product dilution and is controlled by the differential pressure in the seal chamber.

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Installing Tuthill TuffSeall

TM

Cartridge Seals

1. Once pump is fully disassembled (shafts are removed from the impeller housing and faceplate) one can clean stuffing box and shafts thoroughly and examine shaft for wear or scoring. Check bearings for wear as this can cause an eccentric shaft rotation resulting in excessive leakage. If shaft surface is worn, replace shaft or have seal surface area resurfaced.

2. Install new Tuffseal Cartridge seals to the impeller housing and faceplate by fitting the studs into the seal gland slots. Then install the washers and nuts to hold the seal gland onto the stuffing box. These nuts should be tightened finger tight so that the seal assembly can move when the shafts are being installed.

3. During re-assembly, lubricate both of the seal’s O-rings to and make sure the shafts are guided through the Tuffseal collar. Apply even pressure when pushing the shaft through the seal as to not damage the collar O-rings.

4. Once the entire pump is re-assembled, make sure the collar shoulder is seated against the seal spacers.

5. Tighten the seal gland nuts to secure the Tuffseal to the stuffing box.

6. After the pump’s end clearance is set, then tighten the collar setscrews evenly to the shaft.

7. Rotate the spacers away from the collar so that they will not rub against any rotating component when the seal is operating.

Installing Mechanical Seals in Pumps(General)

1. Once pump is fully disassembled (shafts are removed from the impeller housing and faceplate) one can clean stuffing box and shafts thoroughly and examine shaft for wear or scoring. Check bearings for wear as this can cause an eccentric shaft rotation resulting in excessive leakage. If shaft surface is worn, replace shaft or have seal surface area resurfaced.

2. Install new stationary seal seat into the mechanical seal gland. Use a seal lubricant to aid in pressing the seat into the gland. Do not scratch or score the seal face during this process as it will result in a leak.

3. During re-assembly, make sure the mechanical seals and the glands are guided through the shafts as they are installed. Apply even pressure when pushing the shaft through the seal as to not damage the O-rings or seal bellows.

4. Once the entire pump is re-assembled, and the correct end clearance is set, reference the correct working length of the seal.

5. Mark the shaft, through the stuffing box access port, where the correct working length would be on the shaft.

6. Move the seal body to that mark and tighten the seal setscrews. This sets the correct working height of the mechanical seal. Please reference the seal’s manual for the correct working height.

7. Install the seal gland and seal gland gasket to the stuffing box.

8. Tighten the nuts to the seal gland.

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Torque For Shaft Locknuts

Industrial Models

70A, 120A, 330, & 600

Torque (ft-lbs.)

120 – 125

Torque For Faceplate Bolts

Pump Model

600

330

Screw Description Type of Metal

½” Hex Head, 1 ½” LG. P104-1H Note 1 10

½” Socket Head, 1 ½” LG. P105-74 Note 2 4

1/2” Socket Head, 11/8” LG P104-1S4 Note 3 14

½” Hex Head, 1 ¼ “ LG. P104-4H Note 1 8

½” Socket Head, 1 ¼ “ LG. P105-57 Note 2 4

Faceplate Qty. &

Appearance

Applied Torque (ft-lbs)

70 - 75

70 - 75

30 - 35

70 - 75

70 - 75

½” Hex Head, 1 ¼” LG. P104-4H Note 1 13 70 - 75

70A & 120A

½” Hex Head, 1” LG. P104-2H Note 1 1 70 - 75

¼” Socket Head, 1 ½” LG. P105-78 Note 2 4 11 - 14

Note:

• SAE grade 5 steel (Min. tensile strength of 105,000 PSI heat-treated medium carbon)

• High carbon alloy, quenched and tempered (Min. tensile strength of 160,000 PSI)

• Grade 316 stainless steel

Serial Number Location

The serial number will be located on the pump nameplate. In addition, the serial number may be located on the impeller housing top port. Please furnish this number when ordering parts. Pumps with the built-in pressure relief valve must have a top suction port.

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Common Causes of Pump Problems

Symptoms

Possible Causes Suggested Solutions

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Suction line high for vapor pressure of liquid

Liquid too viscous for pump speed

Reduce vacuum requirements

Reduce pump speed

Air leakage in suction piping Tighten and seal all joints

Suction pipe not immersed in liquid

Suction strainer clogged or of insufficient area

Misalignment between pump and driver

Rotating elements binding

Lengthen suction pipe or add liquid to supply tank

Clean strainer or use larger size

Re-align. Check coupling alignment with dial indicator

Pipe strain on pump casing

Relief valve chattering

Excessive system pressure

Disassemble and inspect

Disassemble pipe and re-align before reassembling

Check setting and valve seating

Check for obstructions in discharge line.

Stuffing box packed too tightly

Pump speed to low

Pump parts worn

Repack and adjust

Check pump impeller speed

Have pump reconditioned or replace worn parts

X Obstruction in discharge line Check discharge piping and

Wrong direction of rotation Reverse motor

Suction line sized too small Increase suction piping size

Torque control coupling not adjusted

Readjust coupling

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Troubleshooting

No fluid is delivered

• Power is not on

• Net positive suction head available (NPSHa) is lower than required for the vapor pressure of the liquid pumped

• You should calculate NPSHa and redesign piping, if necessary

• There are leaks in suction line

• Direction of shaft rotation is incorrect

• Relief valve setting is too low (if the pump is equipped with a relief valve). Liquid is discharging through the by-pass port

Capacity is too low

• There are air leaks in suction line

• Suction losses are too high. The suction lift is too great or the suction line is too small or too long

• This can be detected by installing a vacuum gauge directly at the pump suction

• The maximum vacuum at the pump suction should never exceed 15” of mercury

• Vaporization caused by higher vacuums will generally result in capacity drop-off

• Redesign suction conditions

• Pump speed is too slow

• Strainer is too small or obstructed

• Suction pipe or port is not immersed in liquid deep enough

• Piping is improperly installed permitting an air pocket to form in the pump

• Increased clearances or wear in the pump will sometimes cause the pump to deliver an insufficient supply of liquid.

Pump works spasmodically.

• Leaky suction lines

• Suction conditions vary

• Air or vapor is in the liquid

• Problem: Excessive power draw

• Pressure is too high

• Liquid is more viscous than originally expected

• Suction or discharge line is obstructed

• There is insufficient horsepower

• There are mechanical defects

• Drive shaft and pump are misaligned

• Pump is binding due to incorrect clearance setting

• Pump shaft is bent

• Misalignment due to bad piping/poor installation causing strain or distortion

Pump is noisy

• Pump is cavitating due to inadequate suction conditions

• There is misalignment of coupling

• Coupling is set too close to pump

• There is vibration of the pump due to a worn or bent shaft

• There are air leaks on suction side of pump or air entrainment in the fluid

Pump leaks

• Bolts need tightening, allowing gaskets or O-rings to leak

• Gaskets or O-rings are damaged

Note: Packings are designed to leak. Leakage should be at a rate that will prevent excessive heating on the bracket at the packing area.

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Material Returns

If it becomes necessary to return a pump to the factory, a Return Goods Authorization (RGA) must be obtained from either your local

Authorized Distributor or our Alsip plant. No RGA can be issued until a completed Material Safety Data Sheet (MSDS) has been forwarded to our Alsip plant and return of the pump has been approved.

• Tuthill pumps are precision-built and must be handled with care

• Pumps must be drained of all fluid and the ports plugged to prevent foreign material from getting into the pump

• Pumps must be packaged securely to prevent damage while in transit

Warranty

Tuthill Pump Group warrants its products against defective material and workmanship for 90 days from the date of startup or one year from date of shipment from Tuthill’s plant, whichever comes first. This warranty does not include products damaged by tampering, improper installation, abuse, or wear. Nor does it cover consequential damages, or other losses due to pump failure. Because of the unpredictable nature of fluids encountered, pumps are not warranted for any specific life.

Tuthill Pump Group

USA • United Kingdom • China www.tuthillpump.com

Excellence at work. Excellence in life.