Major overhaul. FLYGT 3153

Maintenance

Major overhaul

For a major overhaul, take this action in addition to the tasks listed under Inspection.

Service item Action

Support and main bearing

Mechanical seal

Replace the bearings with new bearings.

Replace with new seal units.

Service in case of alarm

For information about indication values for sensors, see Sensor-connection (page 31).

Alarm source

FLS10

Action

1. Drain the fluid in the inspection chamber. Fill with new coolant if necessary.

2. Check the freezing point (lower than -13°C or 9°F).

Check the inspection chamber again after one week of operation. If leakage has occurred:

1. Drain the fluid.

2. Change the mechanical seal unit.

3. Replace with new coolant.

The thermistor/Thermal contact

The overload protection

1. Check the coolant level (pump with cooling jacket).

2. Check the start and stop levels.

Check that the impeller can rotate freely.

Replace the impeller

Required tools:

• 12 mm hexagon bit adapter with an extension of at least a 100 mm (4 in.)

• Rod (wood or plastic) for locking the impeller in place.

WARNING:

• If you fail with the impeller installation, you must redo the installation procedure from the beginning.

• A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves.

• When laying the pump on its side, do not allow the weight of the pump to rest on any portion of the impeller. The impeller must not be allowed to make contact with the concrete floor or other hard and rough surfaces.

Replace the impeller for wet installation

Remove the impeller: wet installation

CAUTION:

Wear heavy work gloves when you handle impellers. The sharp edges can cause physical injury.

1. Place the pump in a horizontal position.

2. Remove the impeller:

44 Flygt 3153 Installation, Operation, and Maintenance Manual

a) Remove the flush valve cover and its O-ring.

b) Lock the impeller in place by inserting a rod through the hole.

c) Remove the impeller screw.

Maintenance

WS001482A d) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft.

e) Hand-tighten the impeller screw to prevent it from falling off.

f) Remove the rod.

3. Raise the pump.

4. Remove the drive unit from the pump housing:

WS001490A

Flygt 3153 Installation, Operation, and Maintenance Manual 45

Maintenance a) Remove the pump housing screws.

b) Remove the drive unit from the pump housing.

5. Remove the impeller: a) Place the drive unit horizontally.

b) Remove the impeller screw.

46 Flygt 3153 Installation, Operation, and Maintenance Manual

Maintenance c) Remove the impeller and the conical sleeve.

Install the impeller: wet installation

1. Mount the impeller: a) Make sure that the end of the shaft is free from burrs.

Polish off any flaws with a fine emery cloth.

b) Grease the shaft end.

NOTICE:

Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves.

Flygt 3153 Installation, Operation, and Maintenance Manual 47

Maintenance

WS002057A c) Grease the conical sleeve, the threads of the adjustment screw, the washer, and the impeller screw.

Always use a new impeller screw.

d) Adjust the adjustment screw so that it is flush with the sleeve.

48

WS001759A e) Fit the sleeve and impeller to the shaft.

f) Hand-tighten the impeller screw to prevent it from falling off.

Flygt 3153 Installation, Operation, and Maintenance Manual

Maintenance

2. If applicable, check that the clearance between the impeller and the insert ring is maximum 1 mm (0.04 in.) radial. If not, send the pump for service.

The insert ring is pressed into the seal housing cover.

3. Fit the pump housing: a) Fit a new and greased O-ring on the seal housing cover.

b) Grease the pump housing screws.

c) Raise the drive unit.

d) Place the drive unit into the pump housing.

Flygt 3153 Installation, Operation, and Maintenance Manual 49

Maintenance e) Adjust its position so that the inspection hole is on the same side as the flush valve.

f) Tighten the screws in diagonal sequence.

For tightening torque, see Torque values (page 38).

4. Remove the impeller screw: a) Place the pump horizontally.

b) Lock the impeller in place by inserting a rod through the hole.

c) Remove the impeller screw and the washer.

50

WS001482A

5. Adjust the impeller: a) Using a hexagon-bit adapter, turn the adjustment screw clockwise until the impeller makes contact with the pump housing.

For tightening torque, see Torque values (page 38).

b) Tighten it a further 1/8 turn (45°).

Flygt 3153 Installation, Operation, and Maintenance Manual

Maintenance

6. Fasten the impeller: a) Fit the greased washer and impeller screw.

b) Tighten the impeller screw.

For tightening torque, see Torque values (page 38).

c) Tighten it a further 1/8 turn (45°).

WS001486A d) Remove the rod used to lock the impeller.

e) Fit the O-ring and flush valve cover and fasten it with screws.

For tightening torque, see Torque values (page 38).

f) Check that the impeller can rotate freely.

CAUTION:

Beware of the pinch point hazard between the rotating impeller and the guide pin.

7. Check that the clearance between the impeller and the insert ring is 0.1–0.5 mm

(0.004–0.02 in.).

Flygt 3153 Installation, Operation, and Maintenance Manual 51