Maintenance Training Module 2
GlobalGear® with Cartridge Mechanical Seals
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Topics in Maintenance Module 2
Reassembly of Drive Module
Reinstall Drive Module
Adjusting End Clearance
Mechanical Seal Installation
Relief Valve Disassembly & Relief Valve
Troubleshooting
• Servicing High Temperature Greased Bearing Units
• Replacing Bushings
• Lubrication Notes
•
•
•
•
•
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Reassembly of the Drive Module
• Reinstall the rotor into
the bracket
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Reassembly of the Drive Module
• Pick up external ball
bearing
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Reassembly of the Drive Module
• Reinstall bearing into
bearing carrier
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Reassembly of the Drive Module
• Reinstall inner bearing
cap using fasteners
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Reassembly of the Drive Module
• Move cartridge
mechanical seal into
position
• Have flush ports in
correct orientation
• Very loosely tighten
gland nuts
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Reassembly of the Drive Module
• Reinstall bearing
carrier
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Reassembly of the Drive Module
• Push rotor all the way
in the bracket
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Reassembly of the Drive Module
• Insert lock washer with
tabs
• If there is a bearing
spacer, bearing spacer
goes on first
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Reassembly of the Drive Module
• Install locknut
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Reassembly of the Drive Module
Locknut Torque Requirements
Nut Size
Pump Size
Newton-Meters
N-05
GG15-30
68 - 95
N-07
GG120-210
136 – 176
N-08
GG250
163 – 203
KM-12
GG550
163- 203
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Reassembly of the Drive Module
• Bend over tab of lock
washer into slot on
locknut
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Reinstall Drive Module
• Check and make sure
that the gasket is in the
correct position for
flush
• Center of three holes
at flush opening is
correct
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Reinstall Drive Module
• Gasket must align to
allow flow through
internal flush drilling
size GG250 & smaller
• NPT plug indicates
internal flush path at
this location
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Reinstall Drive Module
Position Drive Module Over Foot and Near Housing
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Reinstall Drive Module
Push Drive Module into Housing
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Reinstall Drive Module
Fasten Bolts Connecting Bracket to Housing
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Reinstall Drive Module
Fasten Bolts Connecting Bearing Carrier to Foot
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Adjusting End Clearance
• End clearance is
distance between the
rotor/idler end and the
closest surface on the
cover
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Adjusting End Clearance
• Loosen set screws on
rear cover
• Slowly and gradually
tighten hex nuts on
rear cover until rotor
touches the pump
cover
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Adjusting End Clearance
• When rotor is touching
cover, there will be a
slight drag when
turning the shaft
Key in place
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Adjusting End Clearance
• Measure the gap between
the end the end cover and
the bearing carrier at four
places 90° apart
• Make small adjustments
to set screws and/or hex
nuts so that the gap is the
same at all four measured
points
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Adjusting End Clearance
• Record the gap
measurement with the
rotor touching the cover
• This is zero end clearance
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Adjusting End Clearance
• Refer to TPC 254 for
Tuthill recommended end
clearance
• Add the value from TPC
254 to the gap
measurement for zero
clearance
• This will be the target gap
measurement for end
clearance setting
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Adjusting End Clearance
• Loosen hex bolts,
several complete turns
• Tighten set screws on
rear cover, enough to
achieve the target gap
measurement
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Adjusting End Clearance
• Make adjustments to set
screws & hex nuts so that
the measured gap is the
same 4 points 90° apart
• Do final even tightening of
the set screws/hex nuts &
measure again to confirm
the same measurements
of the gap at 4 points 90°
apart
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Gap is the Same
Adjusting End Clearance
• Final tightening of hex
bolts to secure the rear
cover in place
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Adjusting End Clearance
• If adjustment is being
done in the shop,
clearances can be
measured directly
from the open flanges
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Adjusting End Clearance
• After final tightening
for end clearance,
rotate the shaft by
hand to confirm that
the shaft rotates freely
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Adjusting Radial Clearance
• With cover removed,
check clearance
between rotor outer
diameter and housing
inner diameter at 4
points, 90° apart
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Adjusting Radial Clearance
• Hex nuts can be
adjusted to change
radial rotor position
• Set screws may also
need adjustment
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Final Tightening of Fasteners
Recommend Using a Torque Wrench
Fastener Size
Newton-meters
M6
8 – 12
M8
19 – 28
M10
41 – 54
M12
75 – 88
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Final Tightening of Mechanical Seals
• For all pumps, tightening
of the mechanical seal is
the last step for
reassembling pump
• Gland nuts should only
be barely started
tightened, and seal
cartridge left loosely in
place until the final seal
tightening
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Final Tightening of Mechanical Seals
• Mechanical seal has a
limited travel range for
self alignment, and it is
best to reserve the
travel range for end
clearance adjustments
done in the field
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Final Tightening of Mechanical Seals
• Have flush ports in the
correct position for piping
• Install the mechanical seal
flush and square to the
stuffing box
• Support the seal weight to
center the seal cartridge
on the shaft
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Final Tightening of Mechanical Seals
• Tighten gland nuts in
an even alternating
pattern
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Final Tightening of Mechanical Seals
• Tighten mechanical
seal set screws in an
even alternating
pattern
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Removal of the Relief Valve
• Remove fasteners
securing the relief
valve
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Removal of the Relief Valve
• Relief valve and gasket
removed
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Disassembly of the Relief Valve
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Disassembly of the Relief Valve
• Use large wrench to
remove cap
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Disassembly of the Relief Valve
• Relief valve cap
removed
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Disassembly of the Relief Valve
• Loosen jam nut using
large wrench
• Remove bonnet using
large wrench
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Disassembly of the Relief Valve
• Bonnet removed
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Disassembly of the Relief Valve
• Spring guide removed
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Disassembly of the Relief Valve
• Remove spring
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Disassembly of the Relief Valve
• Orange paint on spring
indicates high pressure
spring, range 10-17
bar for full bypass
• No orange bands
indicates standard
pressure range 3-10
bar for full bypass
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Disassembly of the Relief Valve
• Remove poppet
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Potential Problems with Relief Valves
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Potential Problems with Relief Valves
• Poppet sealing edge
and/or poppet seat
not clean
• Result will be
bypassing
• Corrective action is to
clean the poppet and
seat
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Potential Problems with Relief Valves
• Relief valve chattering
• Relief valve bypassing
flow
• Cause is relief valve set
too low
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Potential Problems with Relief Valves
• Correction is to
increase the setting for
full bypass pressure
• Higher pressure spring
may be required
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Setting Relief Valve in the Field
• Remove cap
• Start pump
• Slowly close discharge
valve completely
• Read pressure gauge
on pump discharge
• This is current full
bypass pressure setting
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Setting Relief Valve in the Field
• Must know highest
normal differential
pressure
• Set relief valve to 50%
higher than highest
normal differential
pressure
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Setting Relief Valve in the Field
1. Loosen jam nut
2. Use adjusting nut to
set pressure on gauge
to target setting
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2.
1.
Setting Relief Valve in the Field
3. Once desired pressure
setting is achieved,
tighten jam nut
4. Replace cap
5. Open discharge valve
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4.
3.
Setting Relief Valve in the Field
• Setting Relief Valve in
the field should be
accomplished in ten
minutes or less
• Do not run the pump
in full bypass for
extended periods to
avoid overheating
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Reassemble Relief Valve
1. Hold relief valve
inverted as shown
2. Drop in poppet, feet
down
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Setting Relief Valve in the Field
3. Drop in spring
4. Drop in spring guide
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4.
3.
Reassemble Relief Valve
• Holding relief valve
inverted
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Reassemble Relief Valve
• Reinstall bonnet using
Teflon pipe dope on
threads
• Reinstall cap using
pipe dope on threads
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Removing High Temp. Greased Bearings
• Remove bearing cover
fasteners
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Removing High Temp. Greased Bearings
• Greased bearings have
a special bearing cover
• Greased bearings have
a grease fitting
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Removing High Temp. Greased Bearings
• Remove bearing cover
• Remove outer bearing
cap hex nuts
• Remove outer bearing
cap
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Removing High Temp. Greased Bearings
• Remove inner bearing
cap fasteners
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Removing High Temp. Greased Bearings
• Push Back Inner
Bearing Cap Toward
Mechanical Seal
Cartridge
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Removing High Temp. Greased Bearings
• Greased bearings are
shrunk onto the shaft
for interference fit
• Must be pulled off
with a bearing puller
• Best practice is not to
reuse a bearing that
has been pulled off a
shaft
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Greasing High Temperature Bearings
• Use recommended
lubricant or equivalent
• Add grease to the
grease fitting using a
grease gun
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Greasing High Temperature Bearings
• Old grease will come
out here
• Old grease will slip
under the lip seal
• Add new grease until a
color change is
observed with the old
grease
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Helpful Hint Carbon Bushings
• Can be pressed out with a
hydraulic press
• Need to be pressed in
with one forceful
movement with no stops
or hesitation
• Stopping mid way or
hesitation may result in
breaking the carbon
bushing
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Helpful Hint Tungsten Carbide Bushings
• Tungsten Carbide
Bushings can be pressed
out with a hydraulic press
• Bracket or idler needs to
be heated to 425° C
before installing tungsten
carbide bushings
• Safety provisions for
handling hot materials
required
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Lubrication Helpful Hints
• Grease and oils designed to take years to break
down
• Contaminants of moisture and particulate from
dust and dirt degrade grease and oils
• Cleanliness is critical
• Tips of grease guns need to be clean
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Lubrication Helpful Hints
• Grease fittings should be cleaned before using
• Work environment should be clean so as to avoid
introducing particulate into grease or oil
• Use manufacturer recommend lubricants or crossover equivalents
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Predictive Maintenance
• Concept of predictive maintenance is to identify the
need for equipment overhaul before a breakdown
• Planned maintenance is less expensive than
responding to break-downs
• Planned maintenance has much less impact on
potential loss of production or disruption to
production schedules
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Predictive Maintenance
How to know when maintenance is necessary?
• Significant increases from baseline recordings for
temperature and/or vibration are indicators of coming
maintenance requirements.
• Bearing temperature increases of 10 °C from baseline is
an alarm level, 20 °C increase over baseline is an
immediate action level.
• Vibration level increases by a factor of 2 above baseline is
an alarm level, vibration increase of 2.5 times baseline is
an immediate action level.
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Predictive Maintenance
Suggestion is to record monthly bearing temp. and vibration readings
• Record temperatures as degrees above ambient
• Bearing temperature from the pump, gear
reducer, and motor
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