5/21/2018 AC 8100 IOM

1/63

A-C Fire PumpInstruction Manual AC2515

REVISION B

8100 SERIESCENTRIFUGAL PUMPS

Installation, Operation, Maintenance

INSTALLER:PLEASE LEAVE THIS MANUAL FOR THE OWNERS USE.

5/21/2018 AC 8100 IOM

2/63

TABLE OF CONTENTS

INTRODUCTION...................................................3 PUMP IDENTIFICATION ..............................3

SAFETY INSTRUCTION...............................4

INSTALLATION....................................................5RECEIVING THE PUMP ...............................5

LIFTING THE PUMP .....................................5

STORAGE.....................................................7

LOCATION ....................................................7

FOUNDATION...............................................7

BASE PLATE SETTING (BEFORE PIPING) 8GROUTING PROCEDURE ...........................9

ALIGNMENT PROCEDURE .........................9

ANSI/OSHA COUPLER GUARDREMOVAL/INSTALLATION ..................9

DOWELING.................................................14

SUCTION AND DISCHARGE PIPING........15

STUFFING BOX LUBRICATION.................17OPERATION.......................................................20

PRE-START CHECKS ................................20

PRIMING .....................................................20

STARTING ..................................................21

OPTIONAL CHECKLIST .............................21SHUTDOWN ...............................................21

FREEZE PROTECTION..............................21

FIELD TESTS..............................................22

MAINTENANCE..................................................23

GENERAL MAINTENANCE AND PERIODICINSPECTION.......................................23

MAINTENANCE OF FLOOD DAMAGEDPUMPS................................................23

LUBRICATION ............................................23

SEAL INFORMATION.................................25

MAINTENANCE TIME TABLE ...........................27TROUBLE SHOOTING.......................................28

TROUBLE SHOOTING (cont.)...........................29SERVICE.............................................................31

DISASSEMBLY AND REASSEMBLYPROCEDURES ...................................31

CHANGING ROTATION .............................31

A. DISMANTLING (PUMP WITH PACKING).............................................................33

ASSEMBLY (PUMP WITH PACKING)........34OPTIONAL METHOD FOR INSTALLING

PACKING (After Pump Disassembly)..37

B. DISMANTLING (PUMP WITH

MECHANICAL SEALS ON SHAFT)....38ASSEMBLY (PUMP WITH MECHANICAL

SEALS ON SHAFT).............................40

C. DISMANTLING (PUMP WITHMECHANICAL SEALS ON SHAFTSLEEVES) ...........................................43

ASSEMBLY (PUMP WITH MECHANICALSEALS ON SHAFT SLEEVES) ...........45

ADJUSTABLE WEAR RINGS.....................48

OIL LUBRICATED BEARINGS...................48

VERTICAL UNITS (MODELS 200, 250, 300)............................................................ 49

INSTRUCTIONS FOR ORDERING PARTS52

APPENDIX A ENGINEERING DATA............. 53APPENDIX B .................................................. 57

EXPLOSION VIEW: PACKING...................57

EXPLOSION VIEW: MECHANICAL SEALSON SHAFT .......................................... 58

EXPLOSION VIEW: MECHANICAL SEALSON SHAFT SLEEVES.........................59

REPLACEMENT PARTS LIST ...................60

APPENDIX C FIELD TEST REPORT ............ 61USEFUL FORMULAS................................. 62

NOTEThe information contained in this book is intendedto assist operating personnel by providinginformation on the characteristics of the purchased

equipment.It does not relieve the user of their responsibility ofusing accepted engineering practices in theinstallation, operation, and maintenance of thisequipment.

Any further questions, contact ITT A-C Pump,(847) 966-3700.

2

5/21/2018 AC 8100 IOM

3/63

INTRODUCTIONWe welcome you as a user of A-C pumps. Yourpump is a product of careful engineering andskilled workmanship. We believe you have thebest pump possible for the service intended. Withcare and preventative maintenance, our A-C

Pump will deliver efficient, trouble-free service.This manual is furnished to acquaint you withsome of the practical ways to install, operate, andmaintain this pump. Read it completely beforedoing any work on your unit and keep it handy forfuture reference.

To maintain this unit at maximum efficiency, followthe recommended installation and servicingprocedures outlined in this manual. To guide in theinstallation of the pump for maximum operatingtime and minimum downtime, you may contact theITT A-C Pump Network of Sales and Service

Representative.

Experienced, factory-trained service personneloffer prompt, efficient service at reasonable rates.These service personnel can find and correctcostly errors such as poor grouting, misalignment,pipe stresses transmitted to the pump casing, orimproperly sized piping. A service person may berequested through your nearest ITT A-C PumpSales Representatives.

Replacement and spare parts, including specialattention to your individual problems, may also beobtained through the ITT A-C Pump

Representative.

For warranty coverages, refer to your salescontract.

PUMP IDENTIFICATION

There are two identification plates on each pump.The pump rating plate gives identification andrating information. Figure 1 shows an example of atypical Rating Plate.

Permanent records for this pump are referencedby the Serial Number and it must, therefore, be

used to order all spare and replacement parts. Thelast digit indicates the specific pump on orders formore than one pump. For example, if an ordercalled for six pumps, all pumps would have thesame first three sets of digits and the last digit willchange to identify each of the six. (e.g. 1-21937-1-1, 1-21937-1-2, etc.)

The identification number is a number which theend user of the pump requests to be put on the

rating plate to identify the pump in his operation.(e.g. CWP-11 stands for Chilled Water Pump No.11)

A-C Pump

ITT Industries

Size Type8X8X17 8100

Serial Number1-21937-1-1

GPM Head (ft.) RPM1500 200 1780

Model Number Imp. Dia. (in.)150 14.80

Max. Field Hydrotest Pressure262 PSI

Identification No. YearCWP-11 2000

MORTON GROVE, IL USA AC0687

FIGURE 1 RATING PLATE

The frame plate, shown below, gives informationconcerning the bearings and their lubrication. Theinboard and outboard bearing numbers refer to thebearing manufacturers numbers.

Frame Inb. Brg.F-20-E4 6039Lubrication Out. Brg.

GREASE 5308Part No. AC0685

FIGURE 2 FRAME PLATE

3

5/21/2018 AC 8100 IOM

4/63

SAFETY INSTRUCTION

The warning and caution decals located on thepump are there for the safety of anyone involvedwith the installation, operation, and maintenanceof the pump. PLEASE READ THE DECALSCAREFULLY.

SAFETYINSTRUCTION

This safety alert symbol will be used in this manualand on the pump safety instruction decals to drawattention to safety related instructions. When usedthe safety alert symbol means ATTENTION!BECOME ALERT! YOUR SAFETY IS INVOLVED!FAILURE TO FOLLOW THE INSTRUCTIONSMAY RESULT IN A SAFETY HAZARD.

WARNING:Do not operate pump at or near zero flow

(closed discharge shutoff valve). Explosion could

result due to large temperature rise in the fluidbeing pumped. Failure to follow these instructionscould result in property damage, severe personalinjury, or death.

WARNING:If pump is to be used on process fluids

above 120F, pump surface temperatures couldbe warm enough to cause burns. Werecommended pump surfaces be insulated orappropriately guarded. Failure to follow theseinstructions could result in severe personal injury.

4

5/21/2018 AC 8100 IOM

5/63

INSTALLATION

RECEIVING THE PUMP

Check the pump for damage immediately uponarrival. (An absolute must!) Prompt reporting of

any damage to the carriers agent, with notationsmade on the freight bill, will expedite satisfactoryadjustment by the carrier.

Pumps and drivers are normally shipped from thefactory mounted on a baseplate. Couplings mayeither be completely assembled or have thecoupling hubs mounted on the shafts and theconnecting members removed. When theconnecting members are removed, they will bepackaged in a separate container and shippedwith the pump or attached to the baseplate.

LIFTING THE PUMPThe following instructions are for the safe lifting ofthe Series 8100 pump.

The pump unit should be unloaded and handledby lifting equally at four or more points on thebaseplate. The lugs on the upper half casing aredesigned for lifting the upper half casing only.

Horizontal

1. Bare Pump (Model 100)

WARNING: Falling Objects Hazard

Eyebolts or lifting lugs, if provided, are forlifting only the components to which they areattached. Failure to follow these instructions couldresult in serious personal injury or death, orproperty damage.

Using a nylon sling, chain, or wire rope,hitch around both bearing supports (SeeFigure 3).

2. Pump, Base, and Driver (Model 150)

Care must be taken to size equipment forunbalanced loads which may exist if the

motor is not mounted on the base at thetime of lifting. Motor may or may not bemounted at the factory.

FIGURE 3 MODEL 100

Pump, base, and driver assemblies wherethe base length exceeds 100 inches maynot be safe to lift as a complete assembly.Damage to the baseplate may occur. If thedriver has been mounted on the baseplateat the factory, it is safe to lift the entireassembly. If driver has not been mountedat the factory and the overall baseplatelengths exceeds 100 inches, do not lift theentire assembly consisting of pump, base,and driver. Instead lift the pump andbaseplate to its final location without thedriver. Then mount the driver.

Bases supplied with lifting holes:

Large bases are supplied with lifting holesin the sides or the ends of the base (SeeFigure 4).

NYLON SLING,CHAIN OR WIREROPE

CHOKER HITCHAROUNDBEARINGFRAME

45MAX

FIGURE 4 MODEL 150

5

5/21/2018 AC 8100 IOM

6/63

Using ANSI/OSHA Standard S hooks,place the S hooks in the holes providedin the four corners of the base. Be surethe points of the hooks do not touch thebottom of the pump base. Attach nylonslings, chains, or wire rope to the Shooks. Size the equipment for the load,and so the lift angle will be less than 45

from the vertical.

Bases supplied without lifting holes:

Place one sling around the outboardbearing housing. Place the remaining slingaround the back end of the motor as closeto the mounting feet as possible. Makesure the sling does not damage thehousing cover or conduit box.

Join the free ends of the slings togetherand place over the lifting hook. Useextreme care when positioning sling under

the motor so it cannot slip off (SeeFigure 5).

FIGURE 5 MODEL 150

Vertical

1. Half Pedestal (Model 200)

WARNING: Falling Objects HazardEyebolts or lifting lugs, if provided, are for

lifting only the components to which they areattached. Failure to follow these instructions couldresult in serious personal injury or death, orproperty damage.

Place nylon sling, chain or wire ropearound both flanges. Use a latch hook orstandard shackle and end loops.

Be sure the lifting equipment is ofsufficient length to keep the lift angle lessthan 30 from the vertical (See Figure 6).

2. Full Pedestal (Model 300)

Install eyebolts in the three holes providedat the top of the support, being sure totighten securely. Attach nylon sling, chain

or wire rope using latch hook or standardshackle and end loop.

FIGURE 6 MODEL 20045MAX

NYLON SLING,CHAIN, ORWIRE ROPE

30

MAX

Be sure to use shoulder eyebolts that aremanufactured per ANSI B18.15 and sizedto fit the holes provided.

Be sure lifting equipment is of sufficientlength to keep the lift angle less than 30from the vertical (See Figure 7).

6

5/21/2018 AC 8100 IOM

7/63

7

FIGURE 7 MODEL 300

STORAGE

The following storage procedures apply to theSeries 8100 pump only. Other accessories suchas motors, steam turbines, gears, etc., must behandled per the respective manufacturersrecommendations.

TemporaryTemporary storage is considered one monthor less. If the pump is not installed andoperated soon after arrival, store it in a clean,dry place that has slow, moderate changes inambient temperature. Rotate the shaftperiodically to coat the bearings with lubricantand to retard oxidation, corrosion, and toreduce the possibility of false brinelling of thebearings. Shaft extensions and otherexposed machine surfaces should be coatedwith an easily removable rust preventativesuch as Ashland Oil Tectyl No. 502C.

For oil lubricated bearings, fill the framecompletely with oil. Before putting equipmentinto operation, drain the oil and refill to properlevel.

Long Term

Storage longer than one month is consideredlong term storage. Follow the sameprocedure for temporary storage with thefollowing addition. Add one half ounce of acorrosion inhibiting concentrated oil such as

Cortec Corp. VCI-329 (for both grease and oillubricated bearings). Seal all vents and applya water proof tape around the oil seals in thebearing frame. Remember for pumps with oillubricated bearings to drain the oil from theframe and refill to the proper level beforerunning the pump.

NYLON SLING,CHAIN, ORWIRE ROPE

30

MAX

LOCATION

The pump should be installed as near to thesuction supply as possible, with the shortest andmost direct suction pipe practical. The totaldynamic suction lift (static lift plus friction losses insuction line) should not exceed the limits for whichthe pump was sold.

When installing the pump, consider its location inrelation to the system to assure that sufficient NetPositive Suction Head (NPSHA) is available at thepump inlet connection. Available NPSH (NPSHA)must always equal or exceed the required NPSH

(NPSHR) of the pump.

The pump must be primed before starting.Whenever possible, the pump should be locatedbelow the fluid level to assure priming. Thiscondition provides a positive suction head on thepump. It is also possible to prime the pump bypressurizing the suction vessel.

The pump should be installed with sufficientaccessibility for inspection and maintenance. Aclear space with ample head room should beallowed for the use of an overhead crane or hoistto lift the unit.

NOTE:Allow a sufficient amount of space todismantle pump without disturbing the pumpsuction and discharge piping.

Select a dry place above the floor level whereverpossible. Take care to prevent pump from freezingduring cold weather when not in operation. Shouldthe possibility of freezing exist during a shut-downperiod, the pump should be completely drained,and all passages and pockets where liquid mightcollect should be blown out with compressed air.

Make sure there is a suitable power source

available for the pump driver. If motor driven, theelectrical characteristics of the power sourceshould be identical to those shown on motor dataplate.

FOUNDATION

The pump is built to provide years of service ifinstalled properly and attached to a suitablefoundation. A base of concrete weighing 2 to 5times the weight of the pump is recommended.

5/21/2018 AC 8100 IOM

8/63

The foundation should be poured withoutinterruption to within 1/2 to 1 inches of thefinished height. The top surface of the foundationshould be well scored and grooved before theconcrete sets; this provides a bonding surface forthe grout.

8

Foundation bolts should be set in concrete as

shown in Figure 8. An optional 4-inch long tubearound the bolts at the top of the concrete willallow some flexibility in bolt alignment to match theholes in the base plate. Allow enough bolt lengthfor grout, shims, lower base plate flange, nuts andwashers. The foundation should be allowed tocure for several days before the base plate isshimmed and grouted.

FIGURE 8 FOUNDATION

BASE PLATE SETTING(BEFORE PIPING)

NOTE:This procedure assumes that a concretefoundation has been prepared with anchor or holddown bolts extending up ready to receive unit. Itmust be understood that pump and motor havebeen mounted and rough aligned at the factory. Ifmotor is to be field mounted, consult factory forrecommendations. ITT A-C Pump CANNOTassume responsibility for final alignment.

FIGURE 9A SETTING BASE PLATE ANDGROUTING YEAR 2000 STYLE BASE FOR

BOTH MOTOR AND ENGINE DRIVEN UNITS

BASEPLATE

SHIMS

GROUT

FORM

BOLTSLEEVE

ANCHOR BOLT

PIPE SLEEVE

FOUNDATIONBOLT

BUILT-UPCONCRETE FOUNDATION

GROUT ONLYTO TOP OFBASE RAIL.

ALLOW 1 FOR SHIMS.PLACE ON BOTH SIDESOF ANCHOR BOLTS.

(OPTIONAL)

CONCRETE

FIGURE 9B GROUTING PRE-YEAR 2000STYLE BASE FOR MOTOR DRIVEN UNITS

a. Use blocks and shims under base forsupport at anchor bolts and midwaybetween bolts, to position baseapproximately 1" above the concretefoundation, with studs extending throughholes in the base plate.

WASHER

b. By adding or removing shims under thebase, level and plumb the pump shaft andflanges. The base plate does not have tobe level.

c. Draw anchor nuts tight against base, and

observe pump and motor shafts orcoupling hubs for alignment. (Temporarilyremove coupling guard for checkingalignment.)

d. If alignment needs improvement, addshims or wedges at appropriate positionsunder base, so that retightening of anchornuts will shift shafts into closer alignment.Repeat this procedure until a reasonablealignment is reached.

NOTE:TO KEEP SHIMS INPLACE ALLOW GROUTTO FLOW AROUNDHOLD DOWN LUGS.

PUMP

BASE RAIL

CONCRETEFOUNDATION

GROUT

LEVELING OF PUMP BASE ONCONCRETE FOUNDATION.

NOTE:Reasonable alignment is defined asthat which is mutually agree upon by pump

contractor and the accepting facility (finaloperator). Final alignment procedures arecovered under Alignment Procedures.

e. Check to make sure the piping can bealigned to the pump flanges withoutplacing pipe strain on either flange.

f. Pour grout in the base plate completely(See Grouting Procedure) and allowgrout to dry thoroughly before attaching

5/21/2018 AC 8100 IOM

9/63

piping to pump. (24 hours is sufficient timewith approved grouting procedure.)

GROUTING PROCEDURE

Grout compensates for uneven foundation,distributes weight of unit, and prevents shifting.Use an approved, non-shrinking grout, after

setting and leveling unit (See Figure 9).

9

a. Build strong form around the foundation tocontain grout.

b. Soak top of concrete foundationthoroughly, then remove surface water.

c. Base plate should be completely filled withgrout.

d. After the grout has thoroughly hardened,check the foundation bolts and tighten ifnecessary.

e. Check the alignment after the foundationbolts are tightened.

f. Approximately 14 days after the grout hasbeen poured or when the grout hasthoroughly dried, apply an oil base paint tothe exposed edges of the grout to preventair and moisture from coming in contactwith the grout.

ALIGNMENT PROCEDURE

NOTE:A flexible coupling will only compensate forsmall amounts of misalignment. Permissible

misalignment will vary with the make of coupling.Consult coupling manufacturers data when indoubt.

Allowances are to be made for thermal expansionduring cold alignment, so that the coupling will bealigned at operating temperature. In all cases, acoupling must be in alignment for continuousoperation. Even though the coupling may belubricated, misalignment causes excessive wear,vibration, and bearing loads that result inpremature bearing failure and ultimate seizing ofthe pump. Misalignment can be angular, parallel,or a combination of these, and in the horizontaland vertical planes. Final alignment should bemade by moving and shimming the motor on thebase plate, until the coupling hubs are within therecommended tolerances measured in total run-out. All measurements should be taken with thepump and motor foot bolts tightened. The shaft ofsleeve bearing motors should be in the center ofits mechanical float.

NOTE:Proper alignment is essential for correctpump operation. This should be performed afterbase plate has been properly set and grout has

dried thoroughly according to instructions. Finalalignment should be made by shimming driveronly. Alignment should be made at operatingtemperatures.

WARNING: Unexpected Start-up HazardDisconnect and lock out power before

servicing. Failure to follow these instructions could

result in serious personal injury or death andproperty damage.

ANSI/OSHA COUPLER GUARDREMOVAL/INSTALLATION

WARNING: Unexpected Start-up HazardDisconnect and lock out power before

servicing. Failure to follow these instructions couldresult in serious personal injury or death andproperty damage.

NOTE:Do not spread the inner and outer guards

more than necessary for guard removal orinstallation. Over spreading the guards may altertheir fit and appearance.

Removal

a. Remove the two capscrews that hold theouter (motor side) coupler guard to thesupport bracket(s).

b. Spread the outer guard and pull it off theinner guard.

c. Remove the capscrew that holds the inner

guard to the support bracket.

d. Spread the inner guard and pull it over thecoupler.

Installation

a. Check coupler alignment beforeproceeding. Correct if necessary.

b. Spread the inner guard and place it overthe coupler.

c. With the inner guard straddling thesupport bracket, install a capscrew

through the hole (or slot) in the supportbracket and guard located closest to thepump. Do not tighten the capscrew.

d. Spread the outer guard and place it overthe inner guard.

e. Install the outer guard capscrews byfollowing the step stated below whichpertains to your particular pump:

i. For pumps with a motor saddle supportbracket:Ensure the outer guard is

5/21/2018 AC 8100 IOM

10/63

straddling the support arm, and installbut do not tighten the two remainingcapscrews.

ii. For pumps without a motor saddlesupport bracket:Insert the spacerwasher between the holes locatedclosest to the motor in the outer guard,

and install, but do not tighten, the tworemaining capscrews.

f. Position the outer guard so it is centeredaround the shaft, and so there is less thana 1/4" of the motor shaft exposed. Onguards that utilize a slotted supportbracket, the inner guard will have to bepositioned so there is only a 1/4" of thepump shaft exposed.

g. Holding the guard in this position, tightenthe three capscrews.

ANSI/OSHA Coupl ing Guard Exploded ViewFor Typical 8100 Series Fire Pump Installation INNER GUARD

OUTER GUARD

ATTACH SUPPORT BRACKETTO BEARING HOUSING

SUPPORTBRACKET

BRACKETSUPPORT

BRACKET SUPPORTATTACHED INSIDE HERE

IN LINE WITH BOLTCAPSCREW

FLAT WASHER

SPACER WASHER

THIS OPTION USED IN PLACE OFSPACER WHERE OVERALL LENGTHOF GUARD EXCEEDS 12 INCHESORGUARD WITH IS OVER 10 INCHESACROSSTHE FLATS.

LOCATE SUPPORT ARMBETWEEN OUTER GUARD ENDS.

ALIGN THE ARM WITH HOLES INTHE OUTER GUARD AND HOLESIN THE SADDLE BRACKET.

NUT

LOCKWASHER

MOTOR SADDLEBRACKET ATTACHTO MOTOR SADDLE

Method 1 Straight Edge Alignment forStandard Sleeve Type Coupler with BlackRubber Insert

(See Figure 10A)

Proceed with this method only if satisfied that

face and outside diameters of the couplinghalves are square and concentric with thecoupling borers. If this condition does notexist or elastomeric couplings do not makethis method convenient, use Method 2.

1. Check angular misalignment using amicrometer or caliper. Measure from theoutside of one flange to the outside of theopposite flange at four points 90 apart.DO NOT ROTATE COUPLER.

Misalignment up to 1/64" per inch ofcoupler radius is permissible.

2. At four points 90 apart (DO NOTROTATE COUPLER), measure theparallel coupler misalignment by laying astraight edge across one coupler half and

measuring the gap between the straightedge and opposite coupler half. Up to a1/64" gap is permissible.

10

5/21/2018 AC 8100 IOM

11/63

FIGURE 10A CHECKING ALIGNMENT

(METHOD 1)

Method 2 For Orange Hytrel Insert , 3500RPM Operation, or All Other CouplerTypes Except as Noted Below

(See Figure 10B)

a. Make sure each hub is secured to itsrespective shaft and that all connectingand/or spacing elements are removed atthis time.

b. The gap between the coupling hubs is setby the manufacturer before the units areshipped. However, this dimension shouldbe checked. (Refer to the coupling

manufacturers specifications suppliedwith the unit.)

c. Scribe index lines on coupling halves asshown in Figure 10B.

d. Mount dial indicator on one hub as shownfor parallel alignment. Set dial to zero.

e. Turn both coupling halves so that indexlines remain matched. Observe dialreading to see whether driver needsadjustment (See paragraph i below).

f. Mount dial indicator on one hub as shownfor angular alignment. Set dial to zero.

g. Turn both coupling halves so that indexlines remain matched. Observe dialreading to see whether driver needsadjustment (See paragraph i below).

h. Assemble coupling. Tighten all bolts andset screw(s). It may be necessary torepeat steps c through f for a final check.

i. For single element couplings, asatisfactory parallel misalignment is.004"T.I.R., while a satisfactory angularmisalignment is .004"T.I.R. per inch ofradius R (See Figure 10B).

STRAIGHT EDGE

FEELER GAGE

PARALLEL

ALIGNMENT

DIALINDICATOR

INCORRECT ALIGNMENT

ANGULAR ALIGNMENT PARALLEL AL IGNMENT

STRAIGHT EDGEINDEX LINE

RESILIENTSEPARATOR

FEELER GAGE

CORRECT ALIGNMENT ANGULARALIGNMENT

DIALINDICATOR

FIGURE 10B CHECKING ALIGNMENT(METHOD 2)

Grid Couplings

NOTE:The following procedure is intendedfor mounting and alignment of RexnordIndustries, LLC. and Clarke Fire ProtectionProducts, Inc., Tapered Grid Couplings.

Adequate lubrication is essential forsatisfactory operation. Grease supplied bythe coupling manufacturer is highlyrecommended. Other greases to be usedshould be approved by the couplingmanufacturer.

Alignment is shown using a spacer bar andstraight edge. Rexnord Industries, LLC. andClarke Fire Protection Products, Inc. statethis practice has been proven for manyindustrial applications. Superior alignmentcan be achieved through the use of dialindicators as shown above.

1. Clean all metal parts using non-flammablesolvent.

2. Lightly coat seals with coupling vendorsupplied grease and place on shaftsbefore mounting shaft hubs.

3. Install keys and mount hubs with flangefaces flush with shaft ends or as otherwisespecified.

4. Reposition hubs on shafts as required toachieve the required hub gap shown inFigure 10H or otherwise specified. Thelength of engagement on each shaft

11

5/21/2018 AC 8100 IOM

12/63

should be roughly equal to the shaftdiameter.

5. Tighten setscrews.

6. Bring the pump and motor halves of thecoupler into approximate height alignment,by placing equal amounts of shims underall the motor feet.

7. Tighten the motor bolts.

8. Use a spacer bar equal in thickness to thegap specified in Figure 10C. Insert bar, asshown below, to same depth at 90intervals and measure clearance betweenbar and hub face with feeler gauges. Thedifference in minimum and maximummeasurements must not exceed theangular installation limits shown in Figure10H.

FIGURE 10C USING SPACER BAR

9. Align so that a straight edge rests (asshown in Figure 10D) on both hubs andalso at 90 intervals without rotating thecoupling. Check with feelers. Theclearance must not exceed thePARALLEL OFFSET installation limitsspecified in Figure 10H.

FIGURE 10D USING STRAIGHT EDGE

10. If adjustment is needed, loosen the motorbolts and add (or remove) an equalamount of shims under each motor foot toalign the height. To correct side

misalignment, strike the side of the motorfoot with a mallet.

11. Tighten the motor bolts and check again.If a correction is made, re-check alignmentin all directions. Repeat this process untilthe desired result is obtained.

12. Pack gap and grooves with coupling

vendor supplied grease before insertinggrid. When grids are furnished in two ormore segments, install them so that all cutends extend in the same direction asshown below. This will ensure correct gridcontact with non-rotating pin in coverhalves.

13. Spread the grid slightly to pass over thecoupling teeth and seat with a soft mallet.

FIGURE 10E SEATING THE GRID

14. Pack the spaces between and around the

grid with as much as coupling vendorsupplied grease as possible and wipe offthe excess until flush with the top of thegrid.

15. Position seals on hubs to line-up withgrooves in cover. Position gaskets onflange of lower cover half and assemblecovers so that the match marks are on thesame side.

12

5/21/2018 AC 8100 IOM

13/63

FIGURE 10F COVER INSTALLATION

16. If the shafts are not horizontal, or couplingis to be used vertically, assemble coverhalves with the lug and match mark UP oron the high side. Push gaskets in untilthey stop against the seals and securecover halves with fasteners, tightening totorque specified in Figure 10H. Ensure

gaskets stay in position during fastenertightening.

FIGURE 10G COVER INSTALLATION,VERTICAL POSITION

17. Ensure the lube plugs are installed in thecover.

WARNING: Coupling Failure

Do not operate coupling without proper lubrication

Failure to follow these instructions could result inserious personal injury or death and propertydamage.

Tightening Torque

Values

Size

Parallel

Offset

(P)

Angular

(x-y)

Hub Gap

+/- 10%

End Float

Physical

Limit (Min)

2xF

Cover Fastener

Tightening Torque

Values

Flange

Type

31 & 35

Maximum

Allow able

RPM Lube Wt.

Max Inch Max Inch Inch Inch

In. Series

Fasteners

(lb*in)

In. Series

Fasteners

(lb*in) lb

1040T 0.006 0.003 0.125 0.211 100 120 3600 0.12

1050T 0.008 0.004 0.125 0.212 200 250 3600 0.15

1060T 0.008 0.005 0.125 0.258 200 440 3600 0.19

1070T 0.008 0.005 0.125 0.259 200 440 1800 0.25

1080T 0.008 0.006 0.125 0.288 200 825 1800 0.38

Installation Limits

FIGURE 10H MISALIGNMENT & FASTENER TORQUE VALUES

13

5/21/2018 AC 8100 IOM

14/63

Final Alignment

Final alignment cannot be accomplished untilthe pump has been operated initially for asufficient length of time to attain operatingtemperature. When normal operatingtemperature has been attained, secure thepump to re-check alignment and compensate

for temperature accordingly. See AlignmentSection.

WARNING: Rotating ComponentsHazard

Do not operate pump without all guards in place.Failure to follow these instructions could result inserious personal injury or death and propertydamage.

WARNING: Coup ling Failure

Do not operate pump with coupling out ofalignment. Ensure final coupling alignment iswithin the values stated above or according to thecoupling manufacturers instructions. Coupling,pump, or driver failure may occur.

Failure to follow these instructions could result inserious personal injury or death and propertydamage.

OPTIONAL Alignment Procedure

If desired, the pump and motor feet can bedoweled to the base after final alignment iscomplete. This should not be done until theunit has been run for a sufficient length oftime and alignment is within the tolerance.See Doweling Section.

CAUTION: Extreme Temperature and/orFlying Debris Hazard

Eye protection and gloves required. Failure tofollow these instructions could result in propertydamage and/or moderate personal injury.

NOTE:Pump may have been doweled tobase at factory.

DOWELING

Pump units may, if desired, be dowelled ondiagonally opposite feet. This should not be doneuntil the unit has been run for a sufficient length of

time and alignment is within the above alignmenttolerance.

DIAL INDICATOR

REFERENCEMARK

SEPARATORS TOTAKE UP BEARING

SLACK

PARALLEL ALIGNMENT ANGULAR ALIGNMENT

FIGURE 11 CHECKING ALIGNMENT (METHOD 2)

14

5/21/2018 AC 8100 IOM

15/63

SUCTION AND DISCHARGE PIPING

The introduction of a pump into a piping systemwhich is not well designed or adjusted may causestrain on the pump, leading to misalignment oreven impeller rubbing. Since slight strain may gounnoticed, final alignment should be done with thesystem full.

Pipe flanges should not impose any strain on thepump. This can be checked by a dial indicator.

Any strain must be corrected by adjustments in thepiping system.

When installing the pump piping, be sure toobserve the following precautions:

Piping should always be run to the pump.

Do not move pump to pipe. This could make finalalignment impossible.

Both the suction and discharge piping should be

independently anchored near the pump andproperly aligned so that no strain is transmitted tothe pump when the flange bolts are tightened. Usepipe hangers or other supports at necessaryintervals to provide support. When expansion

joints are used in the piping system they must beinstalled beyond the piping supports closest to thepump. Tie bolts and spacer sleeves should beused with expansion joints to prevent pipe strain.Do not install expansion joints next to the pump orin any way that would cause a strain on the pumpresulting from system pressure changes. Whenusing rubber expansion joints, follow the

recommendations of the Technical Handbook onRubber Expansion Joints and Flexible PipeConnectors. It is usually advisable to increase thesize of both suction and discharge pipes at thepump connections to decrease the loss of headfrom friction.

Install piping as straight as possible, avoidingunnecessary bends. Where necessary, use 45 orlong radius 90 fittings to decrease friction losses.

Make sure that all piping joints are air-tight.

Where flanged joints are used, assure that insidediameters match properly.

Remove burrs and sharp edges when making upjoints.

Do not spring piping when making anyconnections.

Provide for pipe expansion when hot fluids are tobe pumped.

Suction Piping

When installing the suction piping, observethe following precautions (See Figure 13).

The sizing and installation of the suctionpiping is extremely important. It must beselected and installed so that pressure lossesare minimized and sufficient liquid will flow

into the pump when started and operated.Many NPSH (Net Positive Suction Head)problems can be directly attributed toimproper suction piping systems.

Suction piping should be short in length, asdirect as possible, and never smaller indiameter than the pump suction opening. Aminimum of ten (10) pipe diameters betweenany elbow or tee and the pump should beallowed. If a long suction pipe is required, itshould be one or two sizes larger than thesuction opening, depending on its length.

CAUTION:An elbow should not be used directly

before the suction of a double suction pump if itsplane is parallel to the pump shaft. This can causean excessive axial load or NPSH problems in thepump due to an uneven flow distribution (SeeFigure 12). If there is no other choice, the elbowshould have straightening vanes to help evenlydistribute the flow.

15

5/21/2018 AC 8100 IOM

16/63

WATER VELOCITY INCREASESHERE, CAUSING A GREATERFLOW TO ONE SIDE OF THE

IMPELLERPUMP CASING

CASINGRINGS

SUCTIONELBOW

PUMP SUCTIONFLANGE

IMPELLER

FIGURE 12 UNBALANCED LOADING OF A DOUBLE SUCTION IMPELLERDUE TO UNEVEN FLOW AROUND AN ELBOW ADJACENT TO THE PUMP

Eccentric reducers should be limited to onepipe size reduction each to avoid excessive

turbulence and noise. They should be of theconical type. Contour reducers are notrecommended.

When operating on a suction lift, the suctionpipe should slope upward to the pumpnozzle. A horizontal suction line must have agradual rise to the pump. Any high point inthe pipe can become filled with air andprevent proper operation of the pump. Whenreducing the piping to the suction openingdiameter, use an eccentric reducer with theeccentric side down to avoid air pockets.

NOTE:When operating on suction lift neveruse a concentric reducer in a horizontalsuction line, as it tends to form an air pocketin the top of the reducer and the pipe.

Figure 13 shows some correct and incorrectsuction piping arrangements.

When installing valves in the suction piping,observe the following precautions:

1. If the pump is operating under staticsuction lift conditions, a foot valve may beinstalled in the suction line to avoid the

necessity of priming each time the pumpis started. This valve should be of theflapper type, rather than the multiplespring type, sized to avoid excessivefriction in the suction line. (Under all otherconditions, a check valve, if used, shouldbe installed in the discharge line. SeeDischarge Piping)

2. When foot valves are used, or where thereare other possibilities of water hammer,

close the discharge valve slowly beforeshutting down the pump.

3. Where two or more pumps are connectedto the same suction line, install gatevalves so that any pump can be isolatedfrom the line. Gate valves should beinstalled on the suction side of all pumpswith a positive pressure for maintenancepurposes. Install gate valves with stemshorizontal to avoid air pockets. Globevalves should not be used, particularlywhere NPSH is critical.

4. The pump must never be throttled by theuse of a valve on the suction side of thepump. Suction valves should be used onlyto isolate the pump for maintenancepurposes, and should always be installedin positions to avoid air pockets.

16

5/21/2018 AC 8100 IOM

17/63

FIGURE 13 SUCTION PIPING

ARRANGMENTS

Discharge PipingCHECK VALVE

If the discharge piping is short, the pipediameter can be the same as the dischargeopening. If the piping is long, the pipediameter should be one or two sizes largerthan the discharge opening. On longhorizontal runs, it is desirable to maintain an

even a grade as possible. Avoid high spots,such as loops, which will collect air andthrottle the system or lead to erratic pumping.

GATE VALVESUCTION PIPE INSTALLEDWITH A GRADUAL RISE TO PUMP INCREASER

LEVEL

CENTER LINEOF PIPE CORRECT

AIR POCKET

INCORRECTA slow closing check valve and an isolatinggate valve should be installed in thedischarge line. The check valve (triple dutyvalve), placed between pump and gate valve,protects the pump from excessive backpressure, and prevents liquid from runningback through the pump in case of powerfailure. The gate valve is used in priming andstarting, and when shutting the pump down.

AIR POCKET

INCORRECT

AIR POCKET

Pressure Gauges

Properly sized pressure gauges should beinstalled in both the suction and dischargenozzles in the gauge taps provided. Thegauges will enable the operator to easilyobserve the operation of the pump, and alsodetermine if the pump is operating inconformance with the performance curve. Ifcavitation, vapor binding, or other unstableoperation should occur, widely fluctuatingdischarge pressure will be noted.

INCORRECT

GRADUAL RISETO PUMP

NO AIRPOCKETS

CORRECT

GRADUAL RISETO PUMP

NO AIRPOCKETS

STUFFING BOX LUBRICATIONECCENTRICREDUCER Contaminants in the pumped liquid must not enter

the stuffing box. These contaminants may causesevere abrasion or corrosion of the shaft, or shaftsleeve, and rapid packing or mechanical sealdeterioration; they can even plug the stuffing boxflushing and lubrication system. The stuffing boxmust be supplied at all times with a source ofclean, clear liquid to flush and lubricate thepacking or seal. It is important to establish theoptimum flushing pressure that will keepcontaminants from the stuffing box cavity. If thispressure is too low, fluid being pumped may enterthe stuffing box. If the pressure is too high,excessive packing or seal wear may result; andextreme heat may develop in the shaft causinghigher bearing temperatures. The most desirablecondition, therefore, is to use a seal waterpressure 15-20 psig above the maximum stuffingbox pressure.

CORRECT

DISTANCE PLUSECCENTRIC REDUCERSTRAIGNTENS FLOW

CORRECT

PATH OF WATER

INCORRECT

If the pump system pressure conditions varyduring the day, packing adjustment becomes

17

5/21/2018 AC 8100 IOM

18/63

difficult. Consideration should be given to using amechanical seal. (See Mechanical Seals.)

Packing

Standard pumps are normally packed beforeshipment. If the pump is installed within 60days after shipment, the packing will be in

good condition with a sufficient supply oflubrication. If the pump is stored for a longerperiod, it may be necessary to repack thestuffing box. In all cases, however, inspectthe packing before the pump is started.

NOTE:Packing adjustment is covered in theMaintenance section of this manual.

On some applications, it is possible to useinternal liquid lubrication (pumped liquid) tolubricate packing. Only when all of thefollowing conditions prevail, can this be done:

1. Liquid is clean, free from sediment andchemical precipitation and is compatiblewith seal materials.

2. Temperature is above 32F and below160F.

3. Suction pressure is below 75 psig.

4. Lubrication (pumped liquid) has lubricatingqualities.

5. Liquid is non-toxic and non-volatile.

When the liquid being pumped contains

solids or is otherwise not compatible withpacking materials, an outside supply of sealliquid should be furnished. In general,external-injection liquid (from an outsidesource) is required when any of the aboveconditions cannot be met.

The standard stuffing box consists of rings ofpacking (see assembly section for number ofrings), a seal cage (optional), and a gland. Ashaft sleeve which extends through the boxand under the gland is normally provided toprotect the shaft.

A tapped hole is supplied in the stuffing boxdirectly over the seal cage to introduce aclean, clear sealing medium. The stuffing boxmust, at all times, be supplied with sealingliquid at a high enough pressure to keep thebox free from foreign matter, which wouldquickly destroy the packing and score theshaft sleeve.

Only a sufficient volume of sealing liquid to createa definite direction of flow from the stuffing boxinward to the pump casing is required, but thepressure is important. Apply seal water at a rate ofapproximately .25 GPM at a pressureapproximately 15 to 20 psig above the suctionpressure. (Approximately one (1) drop persecond.)

One recommended method to minimize error inregulating flushing water is a Controlled PressureSystem (Figure 14). It is important to set thepressure reducing valve adjusted to a valueslightly exceeding the maximum stuffing boxoperating pressure (assuming it is reasonablyconstant). A flow indicating device will detect afailing of the bottom packing rings allowingleakage in the pump.

External sealing liquid should be adjusted to thepoint where the packing runs only slightly warm,with a very slow drip from the stuffing box. Excesspressure from an external source can be verydestructive to packing. More pressure is required,however, for abrasive slurries than for clearliquids. Examination of the leakage will indicatewhether to increase or decrease externalpressure. If slurry is present in the leakage,increase the pressure until only clear liquid dripsfrom the box. If the drippage is corrosive orharmful to personnel, it should be collected andpiped away.

A common error is to open the external pipingvalve wide and then control the drippage by

tightening the packing gland. A combination ofboth adjustments is essential to arrive at theoptimum condition. The life of packing and sleevedepends on careful control more than any otherfactor.

FLOWMETER

PRESSUREGUAGE PRESSURE

REDUCINGVALAVE

STUFFING BOX

FIGURE 14 CONTROLLED PRESSURESYSTEM

18

5/21/2018 AC 8100 IOM

19/63

Mechanical Seals

Mechanical seals are preferred over packing onsome applications because of better sealingqualities and longer serviceability. When a seal isproperly installed, it will last longer than packingon similar applications. A mechanical shaft seal issupplied in place of a packed stuffing box when

specifically requested. The change from packingto an alternate arrangement may be made in thefield by competent service personnel. Conversionparts may be order from your ITT A-C Pump SalesRepresentative.

Just as with packing, the mechanical sealchamber must be supplied, at all times, with asource of clean, clear liquid to flush and lubricatethe seal. The most important consideration is toestablish the optimum flushing pressure that willkeep contaminants from the seal cavity. If thispressure is too low, fluid being pumped may enterthe stuffing box. If the pressure is too high,excessive seal wear may result.

When contaminants are present in the systemfluid, an external source of clean seal water mustbe supplied. Supply approximately .25 GPM at apressure approximately 15 to 20 psig above thesuction pressure.

Figure 14 shows the recommended flush systemfor mechanical seal. Water enters the sealchamber, lubricates the seal face, and exits intothe pump itself. Positive flow in the seal water lineindicates adequate seal water pressure.

Cartridge Seals

Follow the appropriate lubrication directions formechanical seals given in this section. Mostcartridge seals provide flushing connections ontheir glands. Use the cartridge seal gland flushingtaps (if provided) for your seal water connectionsinstead of the stuffing box tap. The quench taps onthe glands (if present) are normally only used inchemical applications. Consult seal manufacturersliterature for more detailed information.

Cyclone Sediment Separators

If the fluid being pumped contains sediment andthere is no external, clean water source availableto flush the mechanical seals, a cyclone sedimentseparator can be used to remove most of thesediment from the liquid being pumped so it canbe used to flush the seals. The separator is placedin the seal water piping line and removes thesediment to an external drain (normally back to thepump suction line).

19

5/21/2018 AC 8100 IOM

20/63

OPERATION

PRE-START CHECKS

WARNING: Unexpected Startup HazardDisconnect and lockout power before

servicing. Failure to follow these instructions couldresult in serious personal injury or death, orproperty damage.

WARNING: Electr ical Shock HazardElectrical connections to be made by a

qualified electrician in accordance with allapplicable codes, ordinances, and good practices.Failure to follow these instructions could result inserious personal injury or death, or propertydamage.

Before the initial start of the pump, make the

following inspections:

1. Check alignment between pump andmotor. See the section on alignment foralignment requirements.

2. Check all connections to motor andstarting device with wiring diagram. Checkvoltage, phase, and frequency on motornameplate with line circuit.

3. Check suction and discharge piping andpressure gauges for proper operation.

4. Turn rotating element by hand to assurethat it rotates freely.

5. Check stuffing box adjustment, lubrication,and piping.

6. Check driver lubrication.

7. Assure that pump bearings are properlylubricated.

8. Assure that coupling is properly lubricated,if required.

9. Assure that pump is full of liquid and all

valves are properly set and operational,with the discharge valve closed and thesuction valve open. Purge all air from topof casing.

10. Check rotation. Be sure that the driveroperates in the direction indicated by thearrow on the pump casing as seriousdamage can result if pump is operatedwith incorrect rotation. Check rotation

each time the motor leads have beendisconnected.

PRIMING

If the pump is installed with a positive head on thesuction, it can be primed by opening the suctionvalve, and loosening the vent plug on top of thecasing (Do not remove), allowing air to be purgedfrom the casing.

If the pump is installed with a suction lift, primingmust be done by other methods such as footvalves, ejectors, or by manually filling the casingand suction line.

CAUTION:Under either condition, the pump must be

completely filled with liquid before starting. Thepump must not run dry. Serious damage to thepump may result if it is started dry.

Flushing

New and old systems should be flushed toeliminate all foreign matter. Heavy scale,welding splatter and wire or other largeforeign matter can clog the pump impeller.This will reduce the capacity of the pumpcausing cavitation, excessive vibration,and/or damage to close clearance parts(wear rings, seals, sleeves, etc.).

Filling

Vents should be located at the highest pointso entrained gases and air can escape.However, if the gases are flammable, toxic, orcorrosive they should be vented to anappropriate place to prevent harm topersonnel or other parts of the system. Pipehangers and anchors should be checked tomake sure they are properly set to take theadditional weight of the pumpage.

All drains should be closed when filling the

system. Filing should be done slowly so thatexcessive velocities do not cause rotation ofthe pumping elements which may causedamage to the pump or its driver. Theadequacy of the anchors and hangers maybe checked by mounting a dial indicator off ofany rigid structure not tied to the piping andsetting the indicator button on the pumpflange in the axial direction of the nozzle. Ifthe indicator moves, as the filling proceeds,

20

5/21/2018 AC 8100 IOM

21/63

the anchors and supports are not adequate orset properly and should be corrected.

STARTING

1. Close drain valves and valve in dischargeline.

2. Open fully all valves in the suction line.

3. Slowly turn on seal water to the stuffingbox. (If pumped fluid is dirty or if leakageof air is to be prevented, these linesshould be always left open.)

4. Prime the pump.

NOTE:If the pump does not prime properly,or loses prime during start-up, it should beshutdown and the condition corrected beforethe procedure is repeated.

5. Start the pump driver (turbines and

engines may require warming up; consultthe manufacturers instructions).

6. When the pump is operating at full speed,open the discharge valve slowly. Thisshould be done promptly after start-up toprevent damage to pump by operating atzero flow.

7. Adjust the liquid seal valves to producethe recommended pressure for either themechanical seal or packed stuff box.

OPTIONAL CHECKLIST

1. Driver/Pump Rotation: Check rotationeach time the motor leads have beendisconnected. Be sure that the driveroperates in the direction indicated by thearrow on the pump casing. Roughoperation and extreme vibration can resultif the pump is operated in the wrongdirection.

2. Flow: An accurate measurement of flowrate (volume/time) is difficult in the field.Venturi meters, flow nozzles, orificeplates, or timing the draw down in the wet

well are all possible methods. Record anyreading for future reference.

3. Pressure: Check and record both suctionand discharge pressure gauge readingsfor future reference. Also record voltage,amperage per phase, kilowatts if anindicating wattmeter is available, andpump speed.

4. Temperature: Check and record bearingtemperatures using a thermometer.Temperature should not exceed 180F.

5. Vibration and Sound: The acceptablevibration level of a centrifugal pumpdepends on the rigidity of the pump andthe supporting structure. Recommended

values for vibration can vary between .20ips (inches per second) velocity to .60 ipsvelocity depending on the operatingcharacteristics and the structure. Refer tothe Centrifugal Pump section of theHydraulic Institute Standards for acomplete description and charts onvarious pumps.

Field sound levels are difficult to measure becauseof background noise from piping, valves, drivers,gears, etc. Follow recommendations in theHydraulic Institute Standards.

SHUTDOWN

The following steps will take care of most normalshutdowns of the pump, i.e. maintenance. Makeany further adjustments of process piping, valves,etc., as required. If the pump is to be removedfrom service for an extended period of time, referto the sections on storage and freeze protection.

1. Shut down the driver. (Consultmanufacturers instructions for specialoperations.)

2. Close suction and discharge valves.

3. Close seal liquid valves. (If pumped liquidis dirty, or if inleakage is to be prevented,these lines should always be left open,except when the pump is completelydrained.)

4. Open drain valves as required.

FREEZE PROTECTION

Pumps that are shut down during freezingconditions should be protected by one of thefollowing methods.

1. Drain the pump; remove all liquid from thecasing.

2. Keep fluid moving in the pump andinsulate or heat the pump to preventfreezing.

21

5/21/2018 AC 8100 IOM

22/63

CAUTION:If heat is used to keep the pump from

freezing, do not let the temperature rise above150F.

FIELD TESTS

A typical performance curve for a specific pumpcan be obtained from ITT A-C Pump. This can beused in conjunction with a field test, if one isrequired. All ITT A-C Pump tests and curves arebased on the Hydraulic Institute Standards. Anyfield test must be conducted according to theseStandards.

Unless otherwise specifically agreed, all capacity,head, and efficiencies are based on shop testswhen handling clear, cold, fresh water at atemperature not over 85F.

Appendix C (Page 61) contains a field test report

sheet and some useful equations which can beused when conducting a field test.

22

5/21/2018 AC 8100 IOM

23/63

MAINTENANCE

GENERAL MAINTENANCE AND PERIODICINSPECTION

Operating conditions vary so widely that torecommended one schedule of preventativemaintenance for all centrifugal pumps is notpossible. Yet, some sort of regular inspection mustbe planned and followed. We suggest apermanent record be kept of the periodicinspections and maintenance performed on yourpump. This recognition of maintenance procedurewill keep your pump in good working conditions,and prevent costly breakdowns.

One of the best rules to follow in the propermaintenance of your centrifugal pump is to keep arecord of actual operating hours. Then, after apredetermined period of operation has elapsed,

the pump should be given a thorough inspection.The length of this operating period will vary withdifferent applications, and can only be determinedfrom experience. New equipment, however,should be examined after a relatively short periodof operation. The next inspection period can belengthened somewhat. This system can befollowed until a maximum period of operation isreached which should be considered the operatingschedule between inspections.

MAINTENANCE OF FLOOD DAMAGED PUMPS

WARNING: Unexpected Startup Hazard

Disconnect and lockout power beforeservicing. Failure to follow these instructions couldresult in serious personal injury or death, orproperty damage.

WARNING: Electr ical Shock HazardElectrical connections to be made by a

qualified electrician in accordance will allapplicable codes, ordinances, and good practices.Failure to follow these instructions could result inserious personal injury or death, or propertydamage.

The servicing of centrifugal pumps after a floodedcondition is a comparatively simple matter undernormal conditions.

Bearings are a primary concern on pumping units.First, dismantle the frame, clean and inspect thebearings for any rusted or badly worn surfaces. Ifbearings are free from rust and wear, reassembleand relubricate them with one of the

recommended lubricants. Depending on the lengthof time the pump has remained in the floodedarea, it is unlikely that bearing replacement isnecessary; however, in the event that rust or worn

surfaces appear, it may be necessary to replacethe bearings.

Next, inspect the stuffing box, and clean out anyforeign matter that might clog the box. Packingthat appears to be worn, or no longer regulatesleakage properly should be replaced. Mechanicalseals should be cleaned and thoroughly flushed.

Couplings should be dismantled and thoroughlycleaned. Lubricate the coupling with one of thecoupling manufacturers recommended lubricantswhere required.

LUBRICATION

Grease Lubrication of Bearings

Grease lubricated ball bearings are packedwith grease at the factory and ordinarily willrequire no attention before starting, providedthe pump has been stored in a clean, dryplace prior to its first operation. The bearingsshould be watched the first hour or so afterthe pump has been started to see that theyare operating properly.

A lithium based NLGI-2 grade grease shouldbe used for lubricating bearings where theambient temperature is above -20F. Greaselubricated bearings are packed at the factorywith Shell Alvania No. 2. Other recommendedgreases are Texaco Multifak No. 2 andMobilux No. 2 grease.

Greases made from animal or vegetable oilsare not recommended due to the danger ofdeterioration and forming of acid. Do not usegraphite. Use of an ISO VG 100 mineral baseoil with rust and oxidation inhabitors isrecommended.

In greasing anti-friction bearings, the use ofhigh pressure equipment is not onlyunnecessary, but is actually undesirableunless used with great care. High pressuremay damage the bearings or seals, causeunnecessary loss of grease, create a dangerof overheating due to overgreasing, andproduce unsightly conditions around thebearing. Excess grease is the most commoncause of overheating. Adequate lubrication is

23

5/21/2018 AC 8100 IOM

24/63

assured if the level of grease is maintained atabout the capacity of the bearing and 1/3 to1/2 of the cavity between the bearing andgrease fitting. Any greater amount will, as arule, be discharged by the seal or vent and bewasted.

The importance of proper lubrication cannot

be over emphasized. Lubrication frequencydepends upon the speed, size and type ofbearing, and operating temperature orenvironmental conditions. Generally, thesmaller the bearing and faster the speed, themore frequent the interval for relubricationwith grease. It is recommended that a certainamount of grease be added at intervals ofthree to six months to replace the smallquantity of grease lost between greaseflushing intervals. For average bearinghousing designs, one (1) ounce of grease willbe sufficient at these intervals. For larger or

smaller bearing housings this amount mayhave to be adjusted.

Unfortunately, there is not a grease availablewhich will not harden over time and becomeless suitable for its purpose due to oxidation.It is good practice to remove all the oldgrease about once a year and thoroughlyclean the bearings. This should be doneduring major overhauls. After gainingexperience with each individual pump and itsoperating characteristics, the relubricationand flushing intervals may be adjustedaccordingly. Keep good records and add

grease at regular intervals. Then adjustmentscan be made after the first overhaul, ifnecessary.

Periodic Addition of Grease

Grease lubricated ball bearings are packedwith grease at the factory. Store the pump ina clean, dry place prior to its first operation.

If one is uncertain about the amount ofgrease in a bearing at relubrication intervals,the safe rule is to add grease while the pumpis stopped to avoid overloading. Remember,

a ball or roller bearing in most applications isassured of adequate lubrication if the level ofgrease is maintained at about the capacity ofthe bearing and 1/3 and 1/2 of the cavitybetween the bearing and grease fitting. Anygreater amount will, as a rule, be dischargedby the seals or vent and be wasted. Excessgrease is the most common cause ofoverheating of the bearings. Remove vent

plugs for the first 24 hours of operation afterregreasing.

Bearing Temperature

Normally the maximum desirable operatingtemperature for ball bearings is 180F.Special designs may have higher limits.

Should the temperature of the bearing framerise above the limit, the pump should be shutdown to determine the cause. Check with anaccurate temperature measuring device to besure.

Oil Lubrication of Bearings

Oil lubrication on 8100 Series pumps isconsidered special. Oil lubricated pumps areinstalled with Trico oilers (See Figure 15).The oilers keep the oil level in the housingsconstant.

After the pump has been installed, flush thehousing to remove dirt, grit, and otherimpurities that may have entered the bearinghousing during shipment or installation. Thenrefill the housing with proper lubricant. (Thehousing must be filled using the Trico oiler.)The oil level will be maintained by the Tricooiler. (See the SERVICE section for properinstructions.)

FIGURE 15 TRICO OILER

A Mobil Oil, DTE Medium, or equal, meetingthe following specification will providesatisfactory lubrication. Similar oils can befurnished by all major oil companies. It is theresponsibility of the oil vendor to supply asuitable lubricant.

24

5/21/2018 AC 8100 IOM

25/63

(1) Saybolt viscosity at 100F....215 SSU-240 SSU(2) Saybolt viscosity at 210F......................49 SSU(3) Viscosity index, minimum ..............................95(4) API gravity ................................................28-33(5) Pour point, maximum...............................+20F(6) Flash point, minimum............................... 400F(7) Additives..................Rust & Oxidation inhibitors(8) ISO viscosity..................................................46

NOTE:Oils from different suppliers shouldnot be mixed. Engine oils are notrecommended.

The oil should be a non-foaming, well refined,good grade, straight cut, filtered mineral oil. Itmust be free from water, sediment, resin,soaps, acid and fillers of any kind.

In installations with moderate temperaturechanges, low humidity, and a cleanatmosphere, the oil should be changed afterapproximately 1000 hours of operation. Theoil should be inspected at this time todetermine the operating period before thenext oil change. Oil change periods may beincreased up to 2000-4000 hours based onan 8000 hour year. Check the oil frequentlyfor moisture, dirt, or signs of breakdown,especially during the first 1000 hours.

Do not over oil; this causes the bearings torun hot. The maximum desirable bearinghousing operating temperature for all ballbearings is 180F. Should the temperature ofthe bearing frame exceed 180F (measuredby thermometer) shut down pump to

determine the cause.

Coupling Lubrication

Flexible, rubber element type couplings(Woods Sure-Flex or Falk Wrap Flexcoupling for instance) provide smoothtransmission of power. There is no rubbingaction of metal against rubber to cause wear.Couplings are not affected by abrasives, dirt,or moisture. This eliminates the need forlubrication or maintenance, and providesclean and quiet performance.

If other type of couplings are used, followmaintenance instructions of couplingmanufacturer.

SEAL INFORMATION

Packing (Non-Asbestos)

On packed pumps the packing is installedprior to shipment. All packings used are thehighest grade material. Before pump is put

into operation check the condition of packing.If pump is installed within sixty (60) days aftershipment the packing will be in goodcondition with a sufficient supply oflubrication. If pump is stored for a longerperiod it may be necessary to repack thestuffing box. In all cases, however, werecommend an inspection of the packing

before pump is started.

The standard 8100 series pump packing ismade from braided acrylic yarn impregnatedwith graphite.

A soft, well-lubricated packing reducesstuffing box resistance and preventsexcessive wear on the shaft or shaft sleeve.Many brands of packing on the market havethe desired qualities. Standard packing isJohn Crane Style 1340, or equal.

When a pump with fiber packing is first

started it is advisable to have the packingslightly loose without causing an air leak. Asthe pump runs in, gradually tighten the glandbolts evenly. The gland should never bedrawn to the point where packing iscompressed too tightly and no leakageoccurs. This will cause the packing to burn,score the shaft sleeve and prevent liquid fromcirculating through the stuffing box coolingthe packing. The stuffing box is improperlypacked or adjusted if friction in the boxprevents turning the rotating element byhand. A properly operated stuffing box should

run lukewarm with a slow drip of sealingliquid. After the pump has been in operationfor some time, and the packing has beencompletely run-in, drippage from the stuffingbox should be at least 40 to 60 drops perminute. This will indicate proper packing andshaft sleeve lubrication and cooling.

NOTE:Eccentric run-out of the shaft orsleeve through the packing could result inexcess leakage that cannot be compensatedfor. Correction of this defect is very important.

Packing should be checked frequently and

replaced as service indicates. Six monthsmight be a reasonable expected life,depending on operating conditions. It isimpossible to give any exact predictions. Apacking tool should be used to remove all oldpacking from the stuffing box. Never reuseold and lifeless packing or merely add somenew rings. Make sure the stuffing box isthoroughly cleaned before new packing isinstalled. Also check the condition of the shaft

25

5/21/2018 AC 8100 IOM

26/63

or sleeve for possible scoring or eccentricity,make replacements where necessary.

New packing (non-asbestos) should beplaced carefully into the stuffing box. Ifmolded rings are used, the rings should beopened sideways and the joints pushed intothe stuffing box first. The rings are installed

one at a time, each ring seated firmly and thejoints staggered at about a 90 rotation fromeach preceding joint.

If coil packing is used, cut one ring toaccurate size with either a butt or mitered

joint. An accurately cut butt joint is superior toa poor fitting mitered joint. Fit the ring overthe shaft to assure proper length. Thenremove and cut all other rings to the firstsample. When the rings are placed aroundthe shaft a tight joint should be formed. Placethe first ring in the bottom of the stuffing box.Then install each succeeding ring, staggeringthe joints as described above, making sureeach ring is firmly seated.

Make sure the seal cage is properly locatedin the stuffing box under the sealing waterinlet. The function of the seal cage is toestablish a liquid seal around the shaft,prevent leakage of air through the stuffingbox and lubricate the packing. If it is notproperly located it serves no purpose.

Mechanical Seals

General instructions for operation of thevarious mechanical sealing arrangements areincluded below. It is not feasible to includedetailed instructions for all mechanical sealsin this booklet because of the almostunlimited number of possible combinationsand arrangements. Instead, sealmanufacturers instructions will be includedas a separate supplement to this book, whererequired.

a. Mechanical seals are precision productsand should be treated with care. Usespecial care when handling seals. Clean

oil and clean parts are essential to preventscratching the finely lapped sealing faces.Even light scratches on these faces couldresult in leaky seals.

b. Normally, mechanical seals require noadjustment or maintenance except routinereplacement of worn or broken parts.

c. A mechanical seal which has been usedshould not be put back into service untilthe sealing faces have been replaced orrelapped. (Relapping is generallyeconomical only in seals two inches insize and above.)

Four important rules which should always be

followed for optimum seal life are:

1. Keep the seal faces as clean as possible.

2. Keep the seal as cool as possible.

3. Assure that the seal always has properlubrication.

4. If seal is lubricated with filtered fluid, cleanfilter frequently.

26

5/21/2018 AC 8100 IOM

27/63

MAINTENANCE TIME TABLE

EVERY MONTH Check bearing temperature with a thermometer, not by hand. If bearings arerunning hot (over 180F), it may be the result of too much lubricant. If changing thelubricant does not correct the condition, disassembly and inspect the bearings. Lipseals bearing on the shaft may also cause the housing to run hot. Lubricate lip

seals to correct.EVERY 3 MONTHS Check the oil on oil lubricated units. Check grease lubricated bearings for

saponification. Thiscondition is usually caused by the infiltration of water or otherfluid past the bearing shaft seals and can be noticed immediately upon inspection,since it gives the grease a whitish color. Wash out the bearings with a cleanindustrial solvent and replace the grease with the proper type as recommended.

EVERY 6 MONTHS Check the packing and replace if necessary. Use the grade recommended. Besure the lantern rings are centered in the stuffing box at the entrance of the stuffingbox piping connection.

Take vibration readings on the bearing housings. Compare the readings with thelast set of readings to check for possible pump component failure (e.g. bearings)

Check shaft or shaft sleeve for scoring. Scoring accelerates packing wear.

Check alignment of pump and motor. Shim up units if necessary. If misalignmentreoccurs frequently, inspect the entire piping system. Unbolt piping at suction anddischarge flanges to see if it springs away, thereby indicating strain on the casing.Inspect all piping supports for soundness and effective support of load. Correct asnecessary.

EVERY YEAR Remove the upper half of the casing. Inspect the pump thoroughly for wear, andorder replacement parts if necessary.

Check wear ring clearances. Replace when clearances become three (3) timestheir normal clearance or when a significant decrease in discharge pressure for thesame flow rate is observed. See Engineering Data Section for standardclearances.

Remove any deposit or scaling. Clean out stuffing box piping.

Measure total dynamic suction and discharge head as a test of pump performanceand pipe condition. Record the figures and compare them with the figures of thelast test. This is important, especially where the fluid being pumped tends to form adeposit on internal surfaces. Inspect foot valves and check valves, especially thecheck valve which safeguards against water hammer when the pump stops. Afaulty foot or check valve will reflect also in poor performance of the pump while inoperation.

NOTE:The above time table is based on the assumption that after start-up, the unit had been constantlymonitored and such a schedule was found to be consistent with operation, as shown by stable readings.Extreme or unusual applications or conditions should be taken into consideration when establishing themaintenance intervals.

27

5/21/2018 AC 8100 IOM

28/63

TROUBLE SHOOTINGBetween regular maintenance inspections, be alert for signs of motor or pump trouble. Common symptomsare listed below. Correct any trouble immediately and AVOID COSTLY REPAIR AND SHUTDOWN.

CAUSES CURES

No Liquid Delivered

1. Lack of prime. Fill pump and suction pipe completely with liquid.

2. Loss of prime. Check for leaks in suction pipe joints and fittings; vent casing to removeaccumulated air. Check mechanical seal or packing.

3. Suction lift too high (anegative suction gaugereading).

If there is no obstruction at inlet and suction valves are open, check forpipe friction losses. However, static lift may be too great. Measure withmercury column or vacuum gauge while pump operates. If static lift istoo high, liquid to be pumped must raised or pump lowered.

4. System static head toohigh.

Check with factory to see if a larger impeller can be used; otherwise, cutpipe losses or increase speed or both, as needed. But be careful notto seriously overload driver.

5. Speed too low. Check whether motor is directly across-the-line and receiving full

voltage. Frequency may be too low. Motor may have an open phase.6. Wrong direction of

rotation.Check motor rotation with directional arrow on pump casing. If rotationis correct with arrow, check the relationship of the impeller with casing.(This will require removing casing upper half.) See Figure 16, page 32.

7. No rotation. Check power, coupling, line shaft and shaft keys.

8. Impeller loose on shaft. Check key, locknut and set screws.

9. Impeller completelyplugged.

Dismantle pump and clean impeller.

10. System head or requireddischarge

Check pipe friction losses. Large piping may correct condition. head toohigh. Check that valves are wide open.

Not Enough Liqu id Delivered

11. Air leaks in suction piping. If liquid pumped is water or other non-explosive and explosive gas ordust is not present, test flanges for leakage with flame or match. Forsuch liquids as gasoline, suction line can be tested by shutting off orplugging inlet and putting line under pressure. A will indicate a leak witha drop of pressure.

12. Air leaks in stuffing box. Replace packing and sleeves if appropriate or increase seal lubricantpressure to above atmosphere.

13. Speed too low. See item 5.

14. Discharge head too high. See item 10.

15. Suction lift too large. See item 3.

28

5/21/2018 AC 8100 IOM

29/63

TROUBLE SHOOTING (cont.)

Causes Cures

16. Impeller partially plugged. See item 9.

a. Increase positive suction head on pump by lowering pump or

increasing suction pipe and fittings size.b. Sub-cool suction piping at inlet to lower entering liquid temperature.

17. Cavitation; insufficient

NPSHA (Net PositiveSuction Head Available).

c. Pressurize suction vessel.

18. Defective impeller and/orwear rings.

Inspect impeller and wear rings. Replace if damaged or vane sectionsbadly eroded, or if wear ring clearance is three times normal.

19. Foot valve too small orpartially obstructed.

Area through ports of valve should be at least as large as area ofsuction pipe (preferably 1.5 times). If strainer is used, net clear areashould be 3 to 4 times area of suction pipe.

20. Suction inlet not immerseddeep enough.

If inlet cannot be lowered or if eddies through which air is sucked persistwhen it is lowered, chain a board to suction pipe. It will be drawn intoeddies, smothering the vortex.

21. Wrong direction ofrotation.

Symptoms are an overloaded driver and about one third rated capacityfrom pump. Compare rotation of motor with directional arrow on pumpcasing. If rotation is correct with arrow, impeller may have to be turned180. (See CHANGING ROTATION.)

22. System head too high. See item 4.

23. Defective mechanicalseal.

Repair or replace seal.

Not Enough Pressure

24. Speed too low. See item 5.

25. Air leaks in suction piping

or stuffing box.

See item 11.

26. Mechanical defects. See item 18.

27. Vortex at suction inlet. See item 20.

28. Obstruction in liquidpassages.

Check to see if suction and discharge valves are fully open. Dismantlepump and inspect passages and casing. Remove obstruction.

29. Air or gases in liquid. May be possible to over rate pump to a point where it will provideadequate pressure despite condition. Better provide gas separationchamber on suction line near pump and periodically exhaustaccumulated gas. See item 17.

29

5/21/2018 AC 8100 IOM

30/63

TROUBLE SHOOTING (cont.)

Causes Cures

Pump Operates For Short Time, Then Stops

30. Insufficient NPSHA. See item 17.

31. System head too high. See items 4 and 10.

Pump Takes Too Much Power

32. Head lower than rating;thereby pumping toomuch liquid.

Machine impellers O.D. to size advised by factory or reduce speed.

33. Cavitation See item 17.

34. Mechanical defects. See items 18, 19, 21, and 23.

35. Suction inlet notimmersed.

See item 20.

36. Liquid heavier (in eitherviscosity or specificgravity) than allowed for.

Use larger driver. Consult factory for recommended size. Test liquid forviscosity and specific gravity.

37. Wrong direction ofrotation.

See item 6.

38. Stuffing box glands tootight.

Release gland pressure. Tighten reasonably. If sealing liquid does notflow while pump operates, replace packing.

39. Casing distorted byexcessive strains fromsuction or dischargepiping.

Check alignment. Examine pump for rubbing between impeller andcasing. Replace damaged parts.

40. Shaft bent due to damage through shipment,operation, or overhaul.

Check deflection of rotor by turning on bearing journals. Total indicatorrun-out should nor exceed .002" on shaft and .004" on impeller wearingsurface.

41. Mechanical failure ofcritical pump parts.

Check wear rings and impeller for damage. Any irregularity in theseparts will cause a drag on shaft.

42. Misalignment. Realign pump and driver.

43. Speed may be too high. Check voltage on motor. Check speed versus pump nameplate rating.

44. Electrical defects. The voltage and frequency of the electrical current may be lower thanthat for this motor was built, or there may be defects in motor. Themotor may not be ventilated properly due to a poor location.

45. Mechanical defects inturbine, engine or othertype of drive exclusive ofmotor.

If trouble cannot be located, consult factory.

30

5/21/2018 AC 8100 IOM

31/63

SERVICE

DISASSEMBLY AND REASSEMBLYPROCEDURES

The procedures outlined in this section cover thedismantling and reassembly of three differenttypes of 8100 Series pump construction.

A. 8100 Series pump with packing.

B. 8100 Series pump with mechanical sealson shaft.

C. 8100 Series pump with mechanical sealson shaft sleeves.

Each procedure provides the step-by-stepinstructions for dismantling and then reassemblingthe pump, depending upon the type of shaft sealused.

When working on the pump, use accepted

mechanical practices to avoid unnecessarydamage to parts. Check clearances and conditionsof parts when pump is dismantled and replace ifnecessary. Steps should usually be taken torestore impeller and casing ring clearance when itexceeds three times the original clearance.

If your pump has adjustable wear rings, pleaserefer to the instructions on page 48.

CAUTION:For pumps in the vertical configuration,

(Models 200 and 300) please follow theinstructions for the disassembly and reassembly

of a vertical rotating element on page 49.

CHANGING ROTATION

WARNING: Unexpected Startup HazardDisconnect and lockout power before

servicing. Failure to follow these instructions couldresult in serious personal injury or death, orproperty damage.

WARNING: Electr ical Shock HazardElectrical connections to be made by a

qualified electrician in accordance will allapplicable codes, ordinances, and good practices.Failure to follow these instructions could result inserious personal injury or death, or property

damage.

WARNING: Rotating ComponentsHazard

Do not operate pump without all guards in place.Failure to follow these instructions could result inserious personal injury or death and propertydamage.

8100 Series centrifugal pumps can be operatedclockwise or counterclockwise when viewed fromthe coupling end of the pump. If you wish toreverse the suction and discharge nozzles; i.e.,change rotation, this can be accomplished with thesame pump as follows:

1. Remove the impeller from the shaft, turn it180 and replace it on the shaft. (Followthe disassembly procedures given in thismanual.)

2. With the rotating element out of thecasing, remove the casing from the baseand turn 180. (Factory bases are drilledfor both rotations.)

3. Set the rotating element back in the

casing and reassemble the pump.

NOTE:The impeller and casing are in the samerelationship to each other as they were originally.The shaft and motor are also in the samerelationship to each other as they were originally.

4. Reassemble the pump and realign thecoupling as called for in the alignmentinstructions.

5. The rotation of the motor must bechanged by switching the motor leads.

NOTE:Unless the motor rotation is reversed theimpeller will run backward.

31

5/21/2018 AC 8100 IOM

32/63

CW ROTATION CWW ROTATION

SUCTION

DISCHARGE DISCHARGE

CLOCKWISE ROTATION VIEWEDFROM THE COUPLING END

COUNTER-CLOCKWISE ROTATIONVIEWED FROM THE COUPLING END

FIGURE 16 CORRECT RELATIONSHIP OF IMPELLER AND CASING

DOWEL PIN LOCATION ATPARTING LINE

OPTIONAL INTERNALPIPING WITH SEAL CAGE

PUMP SIZE DIM. "A" PACKING SIZE

3x2x11 8.7553/8

6x4x9 9.312

6x4x10 10.625 1/2

6x4x11 10.750

6x4x129.755

FIGURE 17 ASSEMBLY SECTION: PUMP WITH PACKING

6x4x14

6x6x9 9.312

3/8

8x6x9 9.755

8x6x10 10.625 1/2

8x6x12 9.755 3/8

8x6x12M

8x6x13

8x6x17

8x6x188x8x12

10.625

8x8x17

10x8x12

10x8x17

11.495

10x8x20 11.620

10x10x12

12x10x1212.995

12x10x14

12x10x17

12x10x18

11.495

1/2

32

5/21/2018 AC 8100 IOM

33/63

A. DISMANTLING (PUMP WITH PACKING)

WARNING: Unexpected Start-up HazardDisconnect and lock out power before

servicing. Failure to follow these instructions couldresult in serious personal injury or death, orproperty damage.

WARNING: Electr ical Shock Hazard

Electrical connections to be made by aqualified electrician in accordance with allapplicable codes, ordinances, and good practices.Failure to follow these instructions could result inserious personal injury or death, or propertydamage.

(See exploded view on page 57.)

1. Drain the pump by opening vent plug (A,Figure 18) and remove drain plugs (B andC) on the suction and discharge nozzles.

2. Remove all casing main joint cap screws(2-904-1) and dowels (2-916-1). Removeexternal tubing (0-952-0) if supplied.

3. Insert a screwdriver or pry bar into theslots between the upper and lower casinghalves, and separate the halves, lifting offthe upper casing half. (NOTE:Somecasings have jacking screws.)

FIGURE 18 PUMP WITH PACKING

4. Tap the stuffing boxes with a soft-headedhammer to break the seal between thestuffing box and lower casing half, and liftthe rotating element out of the lowercasing. Rotating element may now bemoved to a suitable working location (SeeFigure 19).

NOTE:A spare rotating element can beinstalled at this point.

FIGURE 19 ROTATING ELEMENT(PACKING INSTALLED)

5. Remove four cap screws (3-904-9) fromeach bearing housing (3-025-3 and -4)and remove the bearings housings fromthe shaft (3-007-0).

6. Bend back lockwasher tab and removelocknut (3-516-4) and lockwasher (3-517-4) from the outboard end of the shaft and,

using a bearing or gear puller, remove thebearing (3-026-4) from the shaft. Removethe inboard end bearing (3-026-3) in thesame manner.

NOTE:Locknut and lockwasher are not usedon inboard end bearing.

CAUTION:DO NOT REUSE THE BALL BEARINGS.

7. Slide both stuffing boxes (3-073-9) off ofthe shaft, working deflector rings (3-136-9)off the shaft at the same time (See Figure

20).

8. Remove lip seals (3-177-9) from thestuffing boxes.

9. Remove the two gland bolts (1-904-9),gland halves (1-014-9), packing (1-924-9)and, if supplied, seal cage (1-013-9) fromeach stuffing box. Remove the O-rings (3-914-1) from the stuffing boxes.

10. Remove the two casing rings (3-003-9)from the impeller (4-002-0) and remove O-rings (3-914-2) from each casing ring.

NOTE:Each casing ring on 10x8x20 and12x10x18 has 2 O-rings (See Figure 21B p.24).

A

VENT PLUG

B

DRAIN PLUG

C

DRAIN PLUG

33

5/21/2018 AC 8100 IOM

34/63

FIGURE 20 REMOVING STUFFING BOX

11. Loosen set screws (3-902-3) in shaft nuts(3-015-9) and then remove shaft nutsusing pin scanner wrench. Remove O-rings (3-914-9) from counterbore in shaftsleeves.

NOTE: Both shaft nuts have right handedthreads.

12. To remove the sleeve, hold the shaftvertically and drop it on a block of wood.The impeller weight should force both theimpeller and sleeve from the shaft. NOTE:There is a silicone adhesive/sealantbetween the sleeve and the impeller.

13. Remove the other shaft sleeve, nut andsleeve O-ring as described in steps 11and 12.

NOTE:For impellers with replaceable rings

remove the rings (0-004-0), if necessary, bycutting with a cold chisel (See Figure 21A).

(3-009-9)SLEEVE

(0-004-0)IMPELLER RING

(3-003-9)CASING RING

LOCKING PIN

(3-943-9)

FIGURE 21A IMPELLER WITH WEAR RINGS

FIGURE 21B FLOATING CASING RING(10X8X20 AND 12X10X18)

14. Remove the impeller key (3-911-1) fromthe shaft.

ASSEMBLY (PUMP WITH PACKING)

All bearings, O-rings, lip seals, gaskets, impellerrings, and casing wear rings should be replacedwith new parts during assembly. All reusable partsshould be cleaned of all foreign matter beforereassembling. The main casing joint gasket can bemade using the upper or lower half as a template.Lay the gasket material on the casing joint. Trim

CASING

(2-001-0)IMPELLER(4-002-0)

CASING

FLOATINGCASING

RINGIMPELLER

34

5/21/2018 AC 8100 IOM

35/63

the gasket, lightly tapping with a ball peen hammerso that it is flush with the inside edges of thecasing.

NOTE:Precut casing gaskets (2-153-5 & 6)can be ordered to minimize the amount oftrimming.

1. Assemble the impeller key (3-911-1) in theshaft key slot.

2. Check the impeller (4-002-0) and casingto determine the correct relationship (SeeFigure 16) and locate the impeller on theshaft per dimension A given in the tableon Figure 17.

NOTE: For impeller with replaceablerings, heat each new ring (0-004-0)(approximately 300-400F for bronze)and slide onto the impeller. Using gloves,hold rings against the impeller shoulderuntil they cool.

3. Starting with the outboard end, apply a1/4" bead of RTV (DOW CORNINGSILICONE SEALANT or equivalent) at theimpeller hub face, making sure to fill upthe keyway.

4. Slide the sleeve (3-009-9) onto shaft,rotating the sleeve to evenly distribute thesealant applied in step 3. Refer toOpt