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TONKAFLO PUMPS
AS SERIES
INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL

For AS9000, AS14000, AS22500 and


AS40000 Pumps
with KZ- and KT-Bearing Frames

Find a contact near you by visiting www.gewater.com and clicking on “Contact Us”.
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GE Water & Process
Technologies
5951 Clearwater Drive
Minnetonka, MN 55343-8995
USA Original
Phone: 952-933-2277 Language
Fax: 952-933-0141
Toll Free: (800) 848-1750

OPERATION & MAINTENANCE MANUAL


SYSTEM: Tonkaflo* Pumps AS Series

SERIES: AS9000, AS14000, AS22500, AS40000 with KZ-


and KT-Bearing Frames

REVISION: C

DATE: October, 2012


Document Number: 1125317

GE Proprietary Information
The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed
to others, or reproduced without the express written consent of GE. If consent is given for reproduction in whole or in part, this notice and the notice set forth on
each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the
U.S. export control laws. Unauthorized export or re-export is prohibited.
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GE Water & Process
Technologies

TONKAFLO PUMPS AS SERIES


AS9000, AS14000, AS22500, AS40000
WITH KZ- AND KT-BEARING FRAMES
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Tonkaflo Pumps AS Series Operation & Maintenance Manual

TABLE OF CONTENTS

Tonkaflo Pumps AS Series

Preface
Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Section 1 - Safety
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Personal Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.2.1 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.2.1.1 Head & Facial Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.2.1.2 Limb Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.3 Safety on Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3.1 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3.2 Electrical & Thermal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3.3 Mechanical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.4 Pinch Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.5 Noise Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.3.6 Pressure & Rupture Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.3.7 Locking Out Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

Section 2 - Overview
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Design Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2.1 Pump Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.3 Materials of Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Section 3 - Pump Installation


3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Upon Arrival. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.4 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.5 Flexible Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.5.1 Coupling Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.6 Piping Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.6.1 Orientation of Inlet Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

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3.6.2 Piping Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5


3.6.2.1 Bypass Piping for Multi-Stage Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3.6.3 Suction Screen (Strainer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3.6.4 Discharge Screen (Strainer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3.6.5 Pump Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3.7 Lubricating The KZ-Bearing Frame Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3.7.1 Setting the KZ-Bearing Frame Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.7.2 Maintaining the Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.7.3 Oil Change/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.8 Lubricating The KT-Bearing Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8.1 Setting the KT-Bearing Frame Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.8.2 Maintaining Oil Level on KT-Bearing Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.8.3 Oil Change Interval for KT-Bearing Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Section 4 - Operating Instructions


4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Priming The Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.3 Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.4 Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.5 Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.6 Troubleshooting Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.6.1 Bearing Frame Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.6.2 Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Section 5 - Maintenance Requirements


5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Tonkaflo Pumps Field Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2.1 Mechanical Seal Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2.2 Removal and Installation of Liquid End Assembly . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2.2.1 Removal of Liquid End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2.2.2 Installation of Liquid End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.2.3 Mechanical Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.2.3.1 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.2.3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.2.4 High-Pressure Mechanical Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5.2.5 KZ- and KT-Bearing Frame Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5.2.5.1 Disassembly of Pumps with KZ- and KT-Bearing Frames . . . . . . . . . . . . . .5-7
5.2.5.2 Bearing Frame Overhaul Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5.2.5.3 Bearing Frame Overhaul Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5.2.5.4 Assembly of Pumps with KZ- and KT-Bearing Frames. . . . . . . . . . . . . . . 5-10
5.2.5.5 Check End Play of KZ- and KT-Bearing Frames.. . . . . . . . . . . . . . . . . . . . . 5-11
5.2.5.6 Install Liquid End and Remount Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.2.6 Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

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5.2.6.1 Replacement of Oil Seal #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13


5.2.6.2 Replacement of Oil Seal #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.2.6.3 Replacement of Oil Chamber Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Section 6 - Material Safety Data Sheets

Section 7 - Service & Support


7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.2 GE W&PT Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.2.1 Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.3 Tonkaflo Service Policy - Liquid Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7.4 Tonkaflo Pump Return Goods Authorization (RGA) Procedure . . . . . . . . . . . . . . . .7-3
7.5 Motor Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.5.1 In-Warranty Pump Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.5.2 Out-of-Warranty Pump Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
7.5.3 Shipping Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
7.5.3.1 In-Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
7.5.3.2 Out-of-Warranty When New Pump is Purchased . . . . . . . . . . . . . . . . . . . . .7-5

Section 8 - Recommended Spare Parts List

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LIST OF TABLES

Table 2.1 - Pump Design Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2


Table 2.2 - Maximum Developed Boost Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Table 2.3 - Pump Name Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Table 2.4 - Materials of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Table 3.1 - Limits of Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Table 3.2 - Coupling Gap Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Table 3.3 - Suction Inlet and Discharge Piping Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Table 3.4 - Typical Heavy-Duty Hydraulic and Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Table 4.1 - Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

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LIST OF FIGURES

Figure 3.1 - Gap Between Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3


Figure 3.2 - Coupling Guard Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Figure 3.3 - Suction Lift Piping Diagram Correct (Left) and Incorrect (Right) . . . . . . . . . . . . .3-6
Figure 3.4 - Discharge Screen Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Figure 3.5 - Initial Cold Setting of Oil Level for KZ-Bearing Frame Pumps . . . . . . . . . . . . . 3-10
Figure 3.6 - KT-Bearing Frame Oil Level Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 5.1 - Separation Of Liquid End Assembly From Bearing Frame . . . . . . . . . . . . . . . . . .5-2
Figure 5.2 - Proper Lifting Method for Liquid End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Figure 5.3 - Removal of Mechanical Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Figure 5.4 - KZ- and KT-Bearing Frame Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Figure 5.5 - Setting Bearing Frame Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

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PREFACE
This manual provides installation, operation, maintenance, and
ownership information for the Tonkaflo Pumps AS Series. It should be
read and internalized in its entirety by all operators.

Failure to adhere to the instructions provided in this manual may


result in severe injury or damage to property, and may render the
warranty null and void.

TYPOGRAPHICAL CONVENTIONS
Typographical conventions used within this manual are defined as
follows:

Bold - indicates a control with which the operator is required to interact.

Bold italicized - indicates important information.

UPPERCASE - indicates the name of a mode or state of operation.

Warns against an unsafe situation or practice that, if not avoided,


could result in property damage.

Warns against an unsafe situation or practice that, if not avoided,


could result in minor or moderate injury.

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Warns against an unsafe situation or practice that, if not avoided,


could result in severe injury or death.

Warns against an unsafe situation or practice that, if not avoided, will


result in severe injury or death.

LIST OF EFFECTIVE PAGES


When updating this document, insert new pages and dispose of
outdated versions before recording all changes using the tables below.

Record the date of each change in the following table:

Change Date Change Date Change Date


0 (original) 4 8
1 5 9
2 6 10
3 7 11

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SECTION 1
SAFETY
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1.1 INTRODUCTION
This section provides general personal and environmental safety
information that applies to all personnel required to work with or around
the Tonkaflo Pumps AS Series.

Material Safety Data Sheets (MSDSs) for chemicals provided by GE W&PT


can be found in Section 6 - Material Safety Data Sheets (MSDSs for
chemicals provided by other manufacturers may be inserted here as
well).

Failure by facility management or operators to adhere to the


information provided in this section may put personnel at significant
risk of injury.

This manual is not intended for repair or overhaul of the Tonkaflo


Pump liquid ends.

Only the factory or Field Service Technician are authorized to repair,


service or overhaul Tonkaflo pump liquid ends.

Before installing or operating a Tonkaflo pump, read all instructions


carefully and keep the manual handy for future reference.

Safety
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1.2 PERSONAL SAFETY


The following sections provide general guidelines regarding personal
safety and cleanliness. Refer to local codes and regulations for more
detailed information.

1.2.1 PERSONAL PROTECTIVE EQUIPMENT


The equipment listed here constitutes the minimum scope of protective
gear that should be available to all operators. Local codes and
regulations may require the use of additional equipment beyond what is
mentioned below.

1.2.1.1 HEAD & FACIAL PROTECTION


• At all times while in the plant operating area, wear a hard hat and
safety glasses with side shields.

• When handling chemicals or working near pressurized lines, (air


and liquid), wear a full face shield.

Read all applicable MSDSs before handling chemicals.

• When exposed to noise levels that exceed 85 dB, wear adequate


hearing protection.

1.2.1.2 LIMB PROTECTION


• When working near pinch or thermal hazards, wear protective
gloves. When handling chemicals, wear chemical-resistant
gloves.

• At all times while in the plant operating area, wear safety boots
with steel toe and shank inserts.

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1.3 SAFETY ON SITE


The following sections provide information regarding general site safety
and proper conduct during various procedures that may be performed
onsite. This information is not intended to replace or override local codes
and regulations.

1.3.1 GENERAL PRECAUTIONS


The following list provides general recommendations intended to ensure
the safety of personnel working in and around the plant operating area:

• Ensure that all personnel have been made familiar with the
proper operating procedures described in this manual.

• Personnel engaged in a procedure that involves obvious risk of


injury should work under the supervision of a colleague prepared
to provide assistance if required.

• Personnel engaged in a procedure they do not feel properly


trained for must cease action immediately and seek advice from
a supervisor.

• When handling pump assembly/parts weighing > 40 lbs, always


use a lifting device.

1.3.2 ELECTRICAL & THERMAL HAZARDS

Only qualified personnel should perform installation and


maintenance procedures for electrical components.

SERVICING ENERGIZED COMPONENTS: Even with the power switch in the OFF
position, certain components inside a device may remain energized. No
service work can be performed until the power supply to the device is
first disconnected.

Safety
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HEATED SURFACES: Areas on certain components, such as pumps, can


become heated to the point where contact with skin will inflict severe
burns. Ensure that all safety guards and other protective measures are
in place and familiarize personnel working with or around the pump.

If there is a bearing failure or inadequate lubrication, the bearing


frame assembly will become very hot: Before performing any
maintenance, allow the bearing frame to cool to room temperature.
Always put on protective gloves before handling hot components.

1.3.3 MECHANICAL HAZARDS


PUMPS: When working with or around pumps, take the following
precautions:

• Before performing maintenance, isolate and drain all piping


connected to a pump.

• Before performing maintenance, turn off power to a pump and


complete all lockout procedures required by government and
plant-specific regulations. Refer to 1.3.7 Locking Out Components
for more information.

• After completing maintenance, replace any guards or other


safety components removed during the procedure.

1.3.4 PINCH HAZARDS

Exposed rotating parts can catch clothing, fingers, or tools and cause
severe personal injury or death.

ROTATING COMPONENTS: Before operating components with rotating parts


or other possible pinch hazards, ensure that all shields, guards, and
emergency kill-switches are in place.

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1.3.5 NOISE HAZARDS


HEARING PROTECTION: When the possibility of exposure to noise levels
greater than 85 db is present, use adequate hearing protection at all
times.

Extended exposure to noise levels greater than 85 db can be harmful


to human hearing.

1.3.6 PRESSURE & RUPTURE HAZARDS


Some pumps are capable of pressurizing lines to as much as 1,000 psi,
and the danger of an explosion due to overpressurization may arise if
proper operating procedures are not observed. In particular, pressure
relief valves should be checked regularly, and tubing used to convey
pressurized air, such as actuated valve air lines (typically operated at 80
psi), should be regularly inspected for cracks.

1.3.7 LOCKING OUT COMPONENTS


When preparing to lock out a device for service, replacement, or repair,
ensure the following:

• All relevant local guidelines and procedures must be observed.

• Only operators qualified to work with the device should perform


a lockout procedure.

• Lockout tags should be applied before performing the lockout


procedure and should be removed only after work has been
completed.

• Lockout tags should be removed only by the person who applied


them.

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SECTION 2
OVERVIEW
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2.1 INTRODUCTION
This section provides a high-level description of the Tonkaflo Pumps AS
Series, including information about performance specifications,
structure, and production process.

2.2 DESIGN SPECIFICATIONS


The instructions provided in this manual refer to the AS9000, AS14000,
AS22500, AS40000 Series of high-pressure Tonkaflo centrifugal pumps
with KZ- and KT-Bearing frames.

The Tonkaflo Pumps AS Series has been designed for reliable service in
many types of pumping applications. The materials of construction
make these pumps suitable for many chemical, corrosive and pure
water applications. Their unique modular design allows the user to
choose the number of stages which most closely match the desired
performance and, thereby, achieve the highest pumping efficiency.

The Tonkaflo Pumps AS Series covers a flow range of 30 to 500 gpm (6.8
to 113.6 m3/hr) with single unit pressures up to 630 psig (43.5 barg).

The capacity and discharge pressures can be increased by operating


pumps in parallel or series. There is no maximum limit on capacity when
operating Tonkaflo pumps in parallel. When operating in series, a
maximum discharge pressure of 1000 psig (69 barg) may be achieved
with high pressure construction on the downstream pump. With inlet
pressure greater than 200 psig (13.8 barg), optional high-pressure
mechanical seals should be used.

Design flow and pressure capacities for the series are detailed in Table
2.1 - Pump Design Capacities and Table 2.2 - Maximum Developed Boost
Pressure respectively.

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Table 2.1 - Pump Design Capacities


AS Series 60 Hz 3500/3565 rpm 50 Hz 2900/2950 rpm
Range Max. No. of Range Max. No. of Max.
Model
gpm (m3/h) Stages - 60 Hz gpm (m3/h) Stages - 50 Hz Efficiency
AS9000 30 - 120 27 25 - 101 29 70%
(6.8 - 27.2) (5.7 - 22.9)
@ 3500 rpm @ 2950 rpm
AS14000 80 - 200 21 68 - 168 24 68%
(18.2 - 45.4) (15.4 - 38.2)
@ 3500 rpm @ 2950 rpm
AS22500 100 - 300 15 83 - 248 15 72%
(22.7 - 68.2) (18.9 - 56.3)
@ 3565 rpm @ 2950 rpm
AS40000 260 - 500 12 215 - 395 15 74%
(59.1 - 113.6) 48.8 - 89.7
@ 3550 rpm @ 2950 rpm

Operating Temperature for Standard Steel stages Note


Maximum Recommended Operating Temperature 200 ºF (93 ºC)

NOTE
• For high temperature applications, consult GE W&PT.
• The temperature stated in this table is for design flow and
pressure. The maximum recommended temperature is
stated on the pump case.

To prevent excessive heat build-up, there must be adequate flow


through the pump at all times.

Table 2.2 - Maximum Developed Boost Pressure


AS Series 60 Hz 60 Hz 3500/3565 rpm 50 Hz 50 Hz 2900/2950 rpm
Model Stages Developed Pressure Stages Developed Pressure
AS9000 27 Up to 640 psig (44.1 barg) 29 Up to 450 psig (31 barg)
@ 3500 rpm @ 2950 rpm
AS14000 21 Up to 450 psig (31 barg) 24 Up to 370 psig (25 barg)
@ 3500 rpm @ 2950 rpm
AS22500 15 Up to 390 psig (26 barg) 15 Up to 270 psig (25 barg)
@ 3565 rpm @ 2950 rpm
AS40000 12 Up to 410 psig (28.3 barg) 15 Up to 350 psig (24.1 barg)
@ 3550 rpm @ 2950 rpm

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2.2.1 PUMP NOMENCLATURE


Table 2.3 - Pump Name Definitions
Example Model AS9022KZC Example Model AS40415KTF-50
AS = All Stainless Steel AS = All Stainless Steel
90 = Series 9000 40 = Series 40000
22 = Number of Stages 4 = Inlet Size (4 in. Victaulic)
KZ = Bearing Frame 15 = Number of Stages
C = Motor Adapter KT = High Thrust Bearing Frame
F = Motor Adapter
-50 = 50 Hz Operation Only

2.3 MATERIALS OF CONSTRUCTION


Table 2.4 - Materials of Construction
Standard Materials of Construction Note
Wetted Castings 316 Stainless Steel
Pump Shaft and Casing 304 Stainless Steel
Impellers and Diffusers 304 Stainless Steel
Mechanical Seal Includes a carbon rotating face
and a ceramic stationary face.
Secondary Sealing Element of Buna-N
Mechanical Seal
Standard Mechanical Seal Crane Type 21
Standard O-Rings Buna-N
Standard Diffuser Bushings Buna-N
Impeller Eye Seals Buna-N
All AS40000 Models Polytrafluoroehylene (PTFE)
AS40000 Models Mechanical Seal Ethylene Propylene (EPDM)

Special Materials of Construction


Optional ethylene propylene (EPDM), Viton*, and Teflon* elastomers are
available. Contact GE W&PT for details.

NOTE
• For liquids other than water, aqueous solutions at elevated
temperatures or corrosive solutes, consult the manufacturer
for compatibility.
* Viton and Teflon are trademarks of E.I. Dupont de Nemours and Company Inc.

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SECTION 3
PUMP INSTALLATION
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3.1 INTRODUCTION
This section provides general information required for installing the
Tonkaflo Pumps AS Series pumps.

This information must be read and understood in its entirety by all


personnel prior to handling, installing or testing the pumps.

3.2 UPON ARRIVAL


All pumps are tested at the factory prior to shipment to ensure they meet
requirements for the order.

• Check the pump upon receipt for possible damage due to


shipping. Report any damage to the carrier immediately.

3.3 LOCATION
• Install the Tonkaflo pump as close as possible to the source of the
liquid to be pumped. It is ideal for the pump to be fed from an
overhead reservoir or from a supply line under positive pressure.

THE Tonkaflo PUMP MUST HAVE POSITIVE PRESSURE AT THE INLET.

• The NPSHR curve shows the minimum positive head required at


the inlet for a given operating capacity.

• If the feedwater source is remote or located several feet away, it


may be necessary to install a transfer pump on the line to ensure
the fluid is pressurized sufficiently for the pump.

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3.4 FOUNDATION
• The foundation for the motor and pump must be sufficiently rigid
and substantial to prevent any significant vibration of the pump
during its operation.

• KZA-Bearing frame pumps should be rigidly mounted at the


bearing frame base to a steel skid or concrete pad. KZB-, KZC-,
KTE-, and KTF-Bearing frame pumps should be rigidly mounted at
the motor base to a steel skid or concrete pad. The bracket at the
discharge end of the pump should be adjusted so that the pump
case is supported in a strain-free manner.

• The pump mounting is to be horizontal and the pump leveled


within 1/16 in./ft (4.5 mm/meter) both in the axial and side-to-
side directions. The pump case and flat boss on the bearing
frame are the best reference for leveling.

Do not force the pump case into a horizontal position.

• Level the pump by shimming the bearing frame base (KZA) or the
motor base (KZB, KZC, KTE, and KTF).

• The pump should be leveled so that the oil level is the same at
both bearing frame bearings. See Table 3.1 - Limits of Leveling for
guidelines.

Table 3.1 - Limits of Leveling


Case Length Level Within
< 4 ft 1/16 in./ft 5.2 mm/meter
4 ft to 8 ft 1/32 in./ft 2.6 mm/meter
> 8 ft 1/42 in./ft 2.0 mm/meter

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3.5 FLEXIBLE COUPLING INSTALLATION


If the pump has been supplied with the motor installed, the coupling is
properly installed.

If the pump has not been supplied as an assembled unit, perform the
following steps:

1. Install the coupling flange on the motor shaft. Do not tighten set
screws until after the pump and motor are assembled.

2. Install the flexible coupling sleeve onto the pump coupling flange
and assemble the pump and motor.

3. Adjust the gap between the coupling flanges to the values shown
in Table 3.2 - Coupling Gap Specifications within +1/16 - 0 in. (+1.5
- 0 mm).

Figure 3.1 - Gap Between Flanges

Table 3.2 - Coupling Gap Specifications


Coupling Size Gap
6 7/8 in. 22.2 mm
7 1 in. 25.4 mm
8 1 -1/8 in. 28.6 mm
9 1-7/16 in. 36.5 mm
10 1-5/8 in. 41.3 mm

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3.5.1 COUPLING GUARD


Coupling guards are available for all Tonkaflo pumps. Check plant safety
requirements.

1. Right Guard (Stamped with ‘B’) 4. Left Guard (Stamped with ‘L’)

2. Lock Washer (4PL) 5. Optional Both Sides (Use this hole


to mount guard if lower hole is not
accessible)

3. #10 Screw (4PL) 6. Use Guard as Template. Mark


Location of Hole. Drill and Tap #10
- 32 UNF (4PL)
Figure 3.2 - Coupling Guard Installation Diagram

3.6 PIPING INSTALLATION

3.6.1 ORIENTATION OF INLET HOUSING


The pump inlet housing has been designed for either upright, or, left or
right horizontal, positioning.

The pump is shipped with the inlet in the upright position. To orient it in
the left or right horizontal position, perform the following steps:

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1. Remove the four (4) bolts holding the suction (inlet) housing to the
bearing frame.

2. Rotate the housing 90º, then, replace the four (4) bolts and
tighten.

3. To prime the pump for installation and prior to start-up, vent any
trapped air by removing the pipe plug at the top of the pump inlet
housing.

3.6.2 PIPING SPECIFICATIONS


• The suction (pump inlet) piping should be of ample size, installed
in direct runs, and have a minimum of bends and restrictions to
minimize pressure loss and to help ensure sufficient suction
pressure to avoid cavitation. When possible, keep the suction
pipe short.

• The suction (inlet) pipe size immediately ahead of the pump inlet
should be sufficiently sized so the pressure available at the pump
suction (inlet) exceeds the Net Positive Suction Head (NPSHR)
required by the pump. Generally, the suction (inlet) piping should
be as outlined in Table 3.3 - Suction Inlet and Discharge Piping
Specifications.
Table 3.3 - Suction Inlet and Discharge Piping Specifications
Pump Model Piping Size - Inlet Piping Size - Discharge
AS9000, AS14000 Pumps 3 in. (7.6 cm) 3 in. (7.6 cm)
AS22500, 40400 Boost Pumps 4 in. (10.2 cm) 4 in. (10.2 cm)
40600 Transfer Pumps 6 in. (15.2 cm) 4 in. (10.2 cm)

• For most pump applications, it is recommended that the pipe size


selected results in frictional line loss of 3 psig/100 ft (0.21 barg/
30.5 m) or less for suction lines, and 10 psig/100 ft (0.69 barg/30.5
m) or less for discharge lines. A larger pipe size will reduce the
frictional line loss.

• The pump inlet piping should be designed to avoid areas where


air may be trapped and accumulated. These air pockets tend to
disrupt pump priming at start-up.

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• To avoid air pockets, suction piping should be kept free of


high points. Suction pipe size changes just ahead of the pump
should be tapered, and eccentric reducers should be used.

• When the pump operates with a suction lift, the suction pipe
should slope upward to the pump from the source of supply,
as detailed in Figure 3.3 - Suction Lift Piping Diagram Correct
(Left) and Incorrect (Right).

1. Long Radius Elbow 6. Check Valve

2. Eccentric Reducer (if used) 7. Foot Valve (if used)

3. Control Shutoff Valve 8. Strainer

4. Suction Pipe (slopes upward) 9. Air pocket created because line


does not slope upward and
eccentric reducer not used

5. Pump 10. Control/Shutoff Valve should not be


used
Figure 3.3 - Suction Lift Piping Diagram Correct (Left) and Incorrect (Right)

• Provisions must be made for priming the pump. To maintain


pump prime, a feed valve can be used with an opening at least as
large as the inlet piping.

• An alternate method would be to use a shutoff valve on the


discharge line and a vacuum pump to draw air out of the
pump and suction line.

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• When pumping liquid from a tank, the suction line must be


submerged enough so air is not drawn into the suction line to
form a vortex. Increasing the size of the inlet pipe to reduce
the velocity will help to prevent the vortex from forming. If
necessary, consult the pump curve to reference the NPSHR.

• Hot liquids within the temperature range of the pump must


have sufficient positive head to prevent vaporization at the
impeller inlet. Consult the factory or your local Tonkaflo
distributor for NPSHA requirements of the pump for your
application.

• The pump must never be throttled on the suction side.

• After installation, test the suction line with water and at least
30 psig (2.1 barg) to detect any leaks.

• The discharge piping should be sized to properly handle the


maximum flow and pressure developed by the pump. Discharge
piping recommendations are outlined in Table 3.3 - Suction Inlet
and Discharge Piping Specifications.

3.6.2.1 BYPASS PIPING FOR MULTI-STAGE PUMPS


• Sufficient flow must be maintained through a multi-stage pump
to prevent the pump from overheating. Low flow rates will result
in excessive energy accumulation and heat build-up in the pump.
Minimum recommended flows are shown in Table 2.1 - Pump
Design Capacities.

• A bypass pipe, that is, a pipe from the discharge piping back to
the source of liquid supply or suction line, may be needed to
ensure that the pump operation is within the specified flow
range. It is recommended that the connection of a bypass pipe to
the suction line be at least 24 in. (61 cm) away from the pump
inlet.

3.6.3 SUCTION SCREEN (STRAINER)


An AS Series Tonkaflo Pump is a precision multi-stage centrifugal pump
with close tolerances to provide maximum efficiency.

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• It is good practice to install a 30 mesh or finer screen (available


as an accessory), or a cartridge filter, in the suction line, to collect
any foreign objects or large particles.

• The pump must not be operated with restricted suction line (inlet)
flow. Positive gauge pressure must be maintained at the pump
inlet (downstream from the filter or screen). A clogged screen or
filter will result in a greater pressure drop.

• A low pressure alarm or shut-off switch located between the


screen or filter and the pump should always be used in
conjunction with a suction line screen or filter.

3.6.4 DISCHARGE SCREEN (STRAINER)


A 30 mesh screen (available as an accessory) located in the discharge
piping will protect the process fluid should the pump be damaged due to
improper operation or other causes.

The installation of the discharge screen is shown in Figure 3.4 - Discharge


Screen Installation Diagram.

1. Discharge Screen 4. Clamp, Victaulic Type

2. Gasket 5. Pipe Adapter

3. Pump Discharge Casting


Figure 3.4 - Discharge Screen Installation Diagram

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3.6.5 PUMP PIPING CONNECTIONS


The standard model Tonkaflo AS9000, AS14000, AS22500, and AS40000
Series pumps have grooved ends, as shown in Figure 3.4 - Discharge
Screen Installation Diagram, to accept Victaulic-type couplings. The
couplings with 1000 psi (69 bar) working pressure rating are available as
an accessory and include a standard Buna-N gasket.

Other gasket materials such as Viton or ethylene propylene (EPDM) are


available. Consult GE W&PT for details.

• The coupling gasket should be thoroughly lubricated before


installation. Silicone grease is recommended.

Petroleum grease, though suitable for most gasket materials, is not


compatible with EPDM.

3.7 LUBRICATING THE KZ-BEARING FRAME


PUMPS

THE BEARING FRAME IS SHIPPED WITHOUT OIL. Two quarts (1.9 L) of


oil are provided with each new Tonkaflo pump. Additional oil can be
purchased from GE W&PT (See Section 8 - Recommended Spare Parts
List).

The bearings are lubricated by maintaining a static oil level within the
bearing frame. Oil circulates from the reservoir through the bearings. An
oil level sight gauge with a “FULL” line is provided with the bearing frame
so the oil level may be viewed and maintained (see Figure 3.5 - Initial Cold
Setting of Oil Level for KZ-Bearing Frame Pumps).

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A heavy-duty premium synthetic oil, Royal Purple Grade Synfilm 68,


should be used. See Table 3.4 - Typical Heavy-Duty Hydraulic and
Lubricating Oil.
Table 3.4 - Typical Heavy-Duty Hydraulic and Lubricating Oil
Manufacturer Description
Tonkaflo Pumps Anti-Wear Synthetic Oil Note
1 Gallon P/N 3097881

NOTE
• See the MSDS for the synthetic oil in Section 6 - Material
Safety Data Sheets.

3.7.1 SETTING THE KZ-BEARING FRAME OIL LEVEL


1. Remove the vent/breather located on the top of the bearing
frame and pour in the oil.

2. Continue adding oil until the “FULL” level line is reached on the
sight gauge (see Figure 3.5 - Initial Cold Setting of Oil Level for KZ-
Bearing Frame Pumps).

1. Vent/Breather 3. ‘Full Line’ Oil Level Sight Gauge

2. Leveling Boss 4. Drain Plug


Figure 3.5 - Initial Cold Setting of Oil Level for KZ-Bearing Frame Pumps

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The bearing frame oil reservoir capacity is approximately 37 ounces


[1 quart, 5 ounce (1.1 L)]. DO NOT OVERFILL THE BEARING FRAME.
Setting the initial cold oil level higher than specified will result in
higher oil operating temperatures and reduced oil life, and possible
leakage from the top of the sight gauge due to expansion.

• The vent/breather is provided to balance the pressure inside the


bearing frame with the surrounding environment. Install the
vent/breather after filling the bearing frame.

Never replace the vent/breather with a solid plug.

3.7.2 MAINTAINING THE OIL LEVEL


• When cold, maintain the oil level at the “FULL” line on the sight
gauge (see Figure 3.5 - Initial Cold Setting of Oil Level for KZ-
Bearing Frame Pumps).

THE PUMP SHOULD NOT BE RUN IF THE OIL LEVEL IS BELOW THE
“FULL” LINE.

During continuous operation, the oil level may rise above the “FULL” line
by approximately 0.25 in. (6.4 mm) due to expansion.

3.7.3 OIL CHANGE/MAINTENANCE

THE RECOMMENDED OIL CHANGE INTERVAL IS 2,000 HOURS OF PUMP


OPERATION OR 6 MONTHS, WHICHEVER OCCURS FIRST.

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• Under extreme temperature variations, high humidity, or dusty/


dirty conditions, oil changes should be more frequent.

• Clean the sight gauge and vent/breather between oil changes.

3.8 LUBRICATING THE KT-BEARING FRAME

THE BEARING FRAME IS SHIPPED WITHOUT OIL. THE TRICO OILER


BOTTLE IS NOT INSTALLED WHEN SHIPPED. THE AUTOMATIC OILER IS
PROVIDED AND USED TO MAINTAIN THE STATIC OIL LEVEL INSIDE THE
BEARING FRAME.

1. Vent/Breather 5. Automatic Oiler Assembly

2. Leveling Boss 6. Oiler Bottle (Shipped Separately)

3. ‘Full Line’ Oil Level Sight Gauge 7. Oil Level of Automatic Oiler (2/3 to
3/4 Full)

4. Crossbar Tips of Level Control to be Adjusted to Same Height as Oil Level Line
on Sight Gauge
Figure 3.6 - KT-Bearing Frame Oil Level Setting

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The KT-Bearing frame includes an automatic oiler assembly. (see Figure


3.6 - KT-Bearing Frame Oil Level Setting).

This feature is distinguishable by the presence of a glass oiler globe on


the exterior of the bearing frame. The automatic oiler is provided and
used to maintain the static oil level inside the bearing frame.

An oil sight gauge, with a “FULL” line, is provided on the bearing frame so
the oil level may be viewed and maintained. Two quarts (1.9 L) of oil is
provided with each new Tonkaflo oil lubricated bearing frame pump.
Additional oil can be purchased from GE W&PT (see Section 8 -
Recommended Spare Parts List).

A heavy-duty hydraulic and lubricating oil (anti-wear, non-detergent,


rust, oxidation, and foam inhibited) should be used. See Table 3.4 -
Typical Heavy-Duty Hydraulic and Lubricating Oil.

3.8.1 SETTING THE KT-BEARING FRAME OIL LEVEL


The removable crossbar level control and bottle support for the oiler was
adjusted at the factory to maintain proper oil level in the bearing frame.

• If adjustment is lost, reset so the crossbar tips are at the same


elevation as when cold - 1/8 in. (3.2 mm) below the “FULL” line on
the oil level sight gauge (see Figure 3.6 - KT-Bearing Frame Oil
Level Setting). The crossbar, level control, oil assembly, and oiler
bottle must be used for proper bearing frame operation. Do not
remove or modify.

• Remove the vent/breather and fill the bearing frame reservoir


until the oil level is at the same height as the “FULL” line on the
sight gauge. Do not try to fill the bearing frame reservoir by
pouring directly into the automatic oiler assembly. For optimum
operation of the automatic oiler, fill the oiler bottle approximately
3/4 full, and place onto the automatic oiler assembly.

• The vent/breather is provided to balance the pressure inside the


bearing frame with the surrounding environment. Install the
vent/breather after filling the bearing frame.

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Never replace the vent/breather with a solid plug.

• The oil level sight gauge is provided with the bearing frame so the
oil level may be viewed before start-up as a check for proper
installation of the automatic oiler.

3.8.2 MAINTAINING OIL LEVEL ON KT-BEARING FRAME


When cold, the oil level can be set 1/8 in. (3.2 mm) below “FULL” line on
the sight gauge (see Figure 3.6 - KT-Bearing Frame Oil Level Setting).

• Maintain oil in the oiler bottle at all times and replenish with fresh
oil. Add oil only when the level drops to the height of the metal
cup of the oiler bottle.

• Before adding oil, loosen the drain plug on the side of the bearing
frame opposite the oiler assembly. Remove 1/3 of oil from the
oiler bottle.

DO NOT OVERFILL THE BEARING FRAME. Setting the initial cold oil
level higher than specified will result in higher oil operating
temperatures, reduced oil life, and possible leakage from the top of
the oil level sight gauge.

3.8.3 OIL CHANGE INTERVAL FOR KT-BEARING FRAME

THE RECOMMENDED OIL CHANGE INTERVAL IS 2,000 HOURS OF PUMP


OPERATION OR 6 MONTHS, WHICHEVER OCCURS FIRST.

• Under extreme temperature variations, high, humidity, or dusty/


dirty conditions oil changes should be more frequent. Clean the
breather and vent/breather between oil changes.

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SECTION 4
OPERATING INSTRUCTIONS
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4.1 INTRODUCTION
This section provides general information and standard operating
procedures (SOPs) for starting up and operating the Tonkaflo Pumps AS
Series. Troubleshooting guidelines are included.

4.2 PRIMING THE PUMP

THE INLET PIPING AND PUMP MUST BE FILLED WITH LIQUID (i.e.
PRIMED) BEFORE START-UP.

• If the pump is below the liquid source or connected to a positive


pressure source, the pump may be primed from that source.

• If the pump is above the liquid source, fill the pump and supply
line with liquid from an external source.

If prime is lost, the pump should be shut off immediately to avoid


overheating and possible damage to the internals of the liquid end.

The pump should not run with a closed discharge for more than 1
minute as the liquid can heat up very quickly and exceed the
maximum operating temperatures, causing irreversible damage to
the wetted internal parts of the liquid end.

NEVER RUN THE PUMP DRY.

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• In order to adequately protect a Tonkaflo pump from running dry,


the following controls are recommended: pressure switches, flow
switches, and temperature switches.

4.3 PUMP ROTATION


• When initially connecting to the power source, confirm that the
motor wiring and available line voltage are the same.

• Connect the wires as shown on the motor wiring diagram located


on the inside of the motor junction box cover or on the nameplate
label.

If a three-phase motor is wired incorrectly, it will cause the pump


shaft to rotate in the wrong direction. This will result in low pressure
(about 1/4 to 1/2 of normal) and flow (about 1/2 of normal). A motor
starter is required for all three-phase motors.

4.4 PRE-START CHECKS

Perform the following steps BEFORE STARTING THREE-PHASE


MOTORS:

1. Prime the pump before applying power, to prevent damage.

2. Apply power for ONE SECOND to check the direction of the motor
shaft rotation. The motor shaft should turn in a clockwise
direction as viewed from the motor end. The direction of rotation
for three-phase motors may be reversed by interchanging any
two leads.

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Tonkaflo Pumps AS Series Operation & Maintenance Manual

4.5 INITIAL OPERATION


With the oil level set (when cold, oil level is maintained at the “FULL” line
on the sight gauge), pump primed, and pump rotation checked, the
pump is ready to operate.

• Upon start-up, check to see that the correct boost pressure is


obtained at design flow.

• If prime was not achieved, reprime as necessary.

4.6 TROUBLESHOOTING GUIDELINES


This section provides general troubleshooting guidelines and
information related to operation of the Tonkaflo Pumps AS Series.

4.6.2 Troubleshooting Chart provides a quick-reference guide to help


identify causes for common issues associated with pump operation.

4.6.1 BEARING FRAME TEMPERATURE


• The operating temperature of the oil lubricated KZ- and KT-
Bearing frame utilized on high- pressure Tonkaflo pumps will vary
depending on the boost pressure of the pump.

• As a general rule, KZ- and KT-Bearing frames will operate within


a temperature range of 130° - 203°F (54° - 95°C).

• During operation, the bearing frame will feel hot to the touch. A
new bearing frame will run cooler after 24 hours of operation.
Bearing frame temperatures will typically decrease further after
a few weeks as the bearing frame assembly breaks in.

• Pumps operating on 50 Hz power (2900 rpm) will operate cooler


than on 60 Hz (3500 rpm).

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GE Water & Process Technologies Tonkaflo Pumps AS Series
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4.6.2 TROUBLESHOOTING CHART


Table 4.1 - Troubleshooting Chart
LOW FLOW
1. Restrictions at Inlet/Discharge.
2. Foot valve operating improperly.
3. Air leak in inlet piping.
4. Air leak in mechanical seal.
5. Inlet suction lift too high.
6. Reverse rotation of pump shaft.
7. Pump not primed adequately.
8. Inlet strainer/filter plugged.

MOTOR RUNS HOT OR STOPS


1. Motor wired improperly.
2. Bad or loose connection.
3. Motor exceeded rated amp draw.
4. Excessive ambient temperature.
5. Heater size too small in motor heater.
6. Binding rotation in the pump shaft.
7. Bearings not adequately lubricated.
8. Specific gravity or viscosity of liquid higher than design conditions.

MOTOR DOES NOT RUN


1. Blown fuse or tripped circuit breaker or overload heater voltage different.
2. Motor too hot - allow to cool.
3. Motor voltage connection and line.
4. Bad connection.
5. Motor wired improperly.

LOW PRESSURE
1. Pump not adequately primed.
2. Air leak in inlet piping.
3. Excessive flow.
4. Clogged suction line filter or screen.
5. Reverse rotation of pump shaft.
6. Foot valve operating improperly.

PUMP VIBRATION
1. Bent pump shaft.
2. Improper mounting/Levelling.

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Table 4.1 - Troubleshooting Chart


LOW FLOW
3. Starved suction (cavitation).
4. Worn bearings.
5. Motor out of balance.

PUMP LEAKING
1. Mechanical seal needs replacing.
2. O-rings in pump casing damaged.
3. Oil seals need replacing.
4. Piping not sealed properly.
5. Vent/Breather dirty or plugged.
6. Oil bottle too full.

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SECTION 5
MAINTENANCE REQUIREMENTS
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GE Water & Process Technologies
Tonkaflo Pumps AS Series Operation & Maintenance Manual

5.1 INTRODUCTION
The information provided in this section is intended as a general
maintenance guide for the Tonkaflo Pumps AS Series.

5.2 TONKAFLO PUMPS FIELD MAINTENANCE

DISCONNECT POWER BEFORE STARTING TROUBLESHOOTING OR


MAINTENANCE.

5.2.1 MECHANICAL SEAL LEAKAGE


• If liquid is leaking from the hole on the bottom, or the holes on
either side of the bearing frame near the inlet, the mechanical
seal may need to be replaced.

• With new pumps, pumps with new mechanical seals, or pumps


which have been dormant for long periods, the seal faces may
not be completely seated and a slight leakage will occur. If this
leakage continues for more than 60 seconds, remove the
discharge piping and tap the pump shaft using a wooden dowel
to seat the seal. Be careful not to damage the pump shaft.

5.2.2 REMOVAL AND INSTALLATION OF LIQUID END


ASSEMBLY

5.2.2.1 REMOVAL OF LIQUID END ASSEMBLY


Removal of the liquid end assembly is required for replacement of the
mechanical seal, or for maintenance work on the pump bearing frame
as described in sections 5.2.3 Mechanical Seal Replacement to 5.2.6 Oil
Seal Replacement.

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GE Water & Process Technologies Tonkaflo Pumps AS Series
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The liquid end may be removed from the bearing frame without
removing the bearing frame from the bedplate or other mounting.

The steps are as follows:

1. Remove the four (4) 3/8-in. bolts and lock washers connecting the
liquid end assembly to the liquid end adapter (see Figure 5.1 -
Separation Of Liquid End Assembly From Bearing Frame).

1. Liquid End Assembly 4. Bearing Frame Assembly

2. Bolts (4) 5. Set Screw

3. Pump Shaft Key 6. 3/16 in Hex Wrench


Figure 5.1 - Separation Of Liquid End Assembly From Bearing Frame

2. Insert a 3/16 in. Allen (hex) wrench in one of the access holes on
either side of the bearing frame toward the liquid end. Rotate the
pump shaft until the Allen wrench slips into the set screw.
Remove the set screw.

3. Loosen the clamp on the discharge end of the pump case.

4. Remove the liquid end assembly (i.e., liquid end of the pump shaft)
by pulling the liquid end away from the bearing frame. Ensure
that the discharge end of the liquid end assembly is supported so
the pump shaft is not bent upon removal.

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The proper lifting method for removal /installation of the liquid end
assembly is illustrated in Figure 5.2 - Proper Lifting Method for Liquid End
Assembly.

Figure 5.2 - Proper Lifting Method for Liquid End Assembly

5.2.2.2 INSTALLATION OF LIQUID END ASSEMBLY


The steps are as follows:

1. Place the shaft key in the pump shaft key way and be sure it is
fully seated.

2. Check to ensure that the anti-seize compound is on the exposed


pump shaft where it engages with the bearing frame shaft. If not,
coat the pump shaft with a small amount of an anti-seize
compound (i.e., Never-Seez or Anti-Seize). The anti-seize
compound is used to prevent corrosion, galvanic pitting, rust, and
seizure. These compounds are available from the factory or local
industrial supply house.

3. Align the keyed pump shaft with the bore of the bearing frame
shaft, and insert the pump shaft such that the key on the pump
shaft fits into the key way on the bearing frame shaft. Then, push
until castings come together.

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4. Fasten together the inlet casting, mechanical seal holder, and


bearing frame assembly with the four (4) 3/8 in. bolts and lock
washers. Reference Figure 5.1 - Separation Of Liquid End
Assembly From Bearing Frame and Figure 5.3 - Removal of
Mechanical Seal for correct placement of parts.

5. After fastening the inlet casting to the bearing frame assembly,


line up the set screw hole in the bearing frame shaft with the
access hole in the bearing frame by rotating the flexible coupling.
Place the set screw in the bearing frame shaft.

6. Through the opening in the discharge casting, push on the end of


the pump shaft with a wooden dowel to seat the shaft in the
bearing frame, then tighten the set screw.

5.2.3 MECHANICAL SEAL REPLACEMENT

5.2.3.1 REQUIRED TOOLS


1. One (1) 3/16 in. Allen (hex) wrench for removal of bearing frame
shaft set screw.

2. 3/8 in. wrench.

5.2.3.2 PROCEDURE
The steps are as follows:

1. Remove the liquid end assembly (see 5.2.2.1 Removal of Liquid


End Assembly).

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2. Remove the pump shaft key and slide the mechanical seal holder
off the pump shaft (see Figure 5.3 - Removal of Mechanical Seal).

1. Liquid End Assembly 5. O-Ring

2. Retaining Ring - DO NOT REMOVE 6. Seal Holder

3. Pump Shaft Extension 7. Pump Shaft

4. Seal Seat, Stationary 8. Seal Rotary Assembly


Figure 5.3 - Removal of Mechanical Seal

3. Remove the rotary portion (spring, washer, and face assembly) of


the seal assembly from the pump shaft by rotating and pulling
the rotary portion until it slides off the pump shaft.

If prying is required, do not damage the pump shaft or inlet housing


where the seal holder seals (see Figure 5.3 - Removal of Mechanical
Seal).

4. When installing a new mechanical seal, do not cut the rubber


bellows when sliding over the shaft key way. Perform the
following steps:

a. To protect the rubber bellows from damage, wrap thin plastic


tape over the shaft key way.

b. Wrap 1-1/4 turns to cover the end of the key way opposite the
shaft end.

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c. With some overlap, continue to wrap the tape until the key
way is covered to the end of the pump shaft.

5. Lubricate the round surface of the pump shaft with soapy water,
oil, petroleum grease, or silicone grease.

6. After lubrication, install the rotary portion of the new seal by


placing it onto the pump shaft and carefully rotating and pushing
the rotary portion down the pump shaft until it is lightly seated
against the spring. Remove the tape.

7. Remove the stationary portion of the mechanical seal from the


cavity in the seal holder (see Figure 5.3 - Removal of Mechanical
Seal).

8. Lubricate the O-ring on the outside of the new stationary seat.


Install the stationary portion into the seal holder cavity. Make
sure the stationary portion is fully seated. Lightly lubricate the
ground surface of the stationary seat with grease or oil.

9. Examine the O-ring on the mechanical seal holder and, if the O-


ring is damaged, replace it with a new one. A new O-ring is
included with the factory-supplied mechanical seal kit. Be sure to
lubricate before installing.

10. Place the mechanical seal holder containing the new stationary
seat onto the pump shaft and slide it down the shaft until fully
engaged with the inlet casing.

CARE MUST BE TAKEN TO NOT DAMAGE THE STATIONARY SEAT WHEN


SLIDING THE ASSEMBLY OVER THE PUMP SHAFT.

11. Install the liquid end assembly onto the bearing frame assembly
(see 5.2.2.2 Installation of Liquid End Assembly).

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5.2.4 HIGH-PRESSURE MECHANICAL SEAL


REPLACEMENT
• High-pressure mechanical seals have the same basic design as
standard mechanical seals. Replace them using the same
procedure outlined in 5.2.3 Mechanical Seal Replacement.

5.2.5 KZ- AND KT-BEARING FRAME MAINTENANCE

5.2.5.1 DISASSEMBLY OF PUMPS WITH KZ- AND KT-BEARING FRAMES


The steps are as follows:

1. Remove the liquid end assembly (see 5.2.2.1 Removal of Liquid


End Assembly).

2. Drain the oil from the bearing frame by removing the oil drain
plug on the lower portion of the bearing frame and then remove
the bearing frame from the motor.

5.2.5.2 BEARING FRAME OVERHAUL PROCEDURE


• For a list of tools required for this procedure, see 5.2.5.3 Bearing
Frame Overhaul Tools.

• For construction of KZ- and KT-Bearing frames, refer to Figure 5.4


- KZ- and KT-Bearing Frame Overhaul.

If there is a bearing failure or inadequate lubrication, the bearing


frame assembly will become very hot: Before performing any
maintenance, allow the bearing frame to cool to room temperature.
Always put on protective gloves before handling hot components.

The steps are as follows:

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1. Remove the four (4) bolts and lock washers that fasten the motor
adapter to the motor side of the bearing frame. Separate the
adapter from the bearing frame.

2. Remove retaining ring #1 from the bearing frame as shown in


Figure 5.4 - KZ- and KT-Bearing Frame Overhaul.

1. Bearing Cups 10. Oil Chamber Bulkhead

2. Bearing #1 11. Oil Drain Plug

3. O-Ring 12. Oil Seal #2

4. Retaining Ring #1 13. O-Ring

5. Oil Seal #1 14. Adapter, Motor Bearing Frame

6. Retaining Ring #2 15. Bolts (4)


7. Oil Seal Holder 16. Locknut

8. Bearing Frame 17. Lock Washer

9. Flat Washer 18. Tanged Flat Washer


Figure 5.4 - KZ- and KT-Bearing Frame Overhaul

3. Remove the lock nut, lock washer, and flat washer from the
bearing frame shaft.

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4. Place the bearing frame in a press. Simultaneously press out on


the oil seal holder and remove bearing cone #2 from the shaft by
pressing on the motor end of the bearing frame shaft. After the
oil seal holder is removed, continue pressing to remove the shaft
assembly from the bearing frame. Bearing cone #1 will remain on
the shaft.

• Removal of bearing cone #1 from the shaft should be done


only when replacement is necessary.

5. Inspect the bearing cups and cones for any rough surface
conditions and replace both cup and cone when necessary.
Pitted and galled rollers and/or bearing cap indicates
replacement is necessary.

• Very light marks from the bearing cage may form around
roller during “break-in period”. This is not a problem and
bearing replacement is not necessary.

6. To remove the bearing cup(s) from the bearing frame, use a brass
or soft steel rod and hammer to knock them out.

7. Inspect both oil seals and replace if the seals are no longer pliable
or if they are leaking.

5.2.5.3 BEARING FRAME OVERHAUL TOOLS


1. Two 5/16-in. x 18 UNC x 2-1/2-in. bolts for removal of grease seal
holder.

2. One 3/8-in. bolt to hold bearing frame shaft when removing lock
nut.

3. One 3/16-in. Allen (hex) wrench for removal of bearing frame


shaft set screw.

4. Bearing press (arbor press).

5. Dial indicator for setting bearing frame shaft end play.

Retaining ring pliers for removal of retaining ring from K-Bearing frame
shaft (Truarc L1520 or equivalent).

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5.2.5.4 ASSEMBLY OF PUMPS WITH KZ- AND KT-BEARING FRAMES


The steps are as follows:

1. If removed, press new bearing cup(s) into the bearing frame,


making sure they are fully seated.

2. If removed, press bearing cone #1 (see Figure 5.4 - KZ- and KT-
Bearing Frame Overhaul) onto the shaft, holding the bearing
square with the shaft while starting. Make sure the washer
behind bearing cone #1 has been replaced.

• The correct set-up may be checked by placing the shaft into


the bearing frame and measuring 2.772 - 0.010-in. (70.41 -
0.025 mm) recess. Refer to Figure 5.5 - Setting Bearing Frame
Shaft End Play. Apply only enough press force to fully seat the
bearing against the washer and retaining ring.

Do no apply excessive force, which will distort the retaining ring.

3. With the shaft in the bearing frame, press on the second bearing
cone, holding it square with the shaft while starting. Press until
the bearing cone is fully seated against the bearing cup and
there is no end play.

4. Reinstall the tanged flat washer, lock washer, and nut. Hand
tighten the lock nut (left-handed thread) and lightly set a tang on
the lock washer into a slot on the lock nut. If desired, a 3/8-16NC
x 3 bolt may be inserted through a side port in the bearing frame
and into the set screw hole in the end of the bearing frame shaft
(see Figure 5.3 - Removal of Mechanical Seal) when tightening the
lock nut.

5. Using a press, force bearing cone #2 back against the tanged flat
washer by pressing on the motor end of the shaft. This sets the
bearing so that the shaft end play may be checked.

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Do not apply excessive force which would distort the threads on the
shaft and lock nut.

6. Check the end play of the shaft (see 5.2.5.2 Bearing Frame
Overhaul Procedure and Figure 5.4 - KZ- and KT-Bearing Frame
Overhaul).

5.2.5.5 CHECK END PLAY OF KZ- AND KT-BEARING FRAMES.

1. Dial Indicator 3. Bearing Frame Shaft

2. Move Shaft To Check End Play 4. Set Tang Into Slot


Figure 5.5 - Setting Bearing Frame Shaft End Play

The steps are as follows:

1. Grasp the shaft on the motor side of the bearing frame while
turning the shaft as far as it will go. This ensures that the bearing
cone is completely seated in the bearing race.

2. Hold the shaft in place to prevent axial movement.

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3. Zero out and set the dial indicator as shown in Figure 5.5 - Setting
Bearing Frame Shaft End Play.

4. Push the shaft back toward the motor side of the bearing frame
and observe the movement on the dial indicator. The end play
should read 0.011 - 0.014-in. (0.28 - 0.36 mm).

5. Repeat Step 4. two to three times to verify end play accuracy.

NOTE: End play of 0.011 - 0.014 in. (0.28 - 0.36 mm) or less is difficult
to read by hand. GE recommends using a dial indicator to measure
end play.

6. If further adjustment is necessary, press bearing cone #2 to


reseat it against the bearing cup.

7. Tighten or loosen the lock nut as required. Advancement of the


nut until the next lock washer tang is aligned results in 0.0008-in.
(0.02 mm) less end play. Advancing the lock nut until the same
notch lines up with the next lock washer tang results in 0.003-in.
(0.08 mm) less end play.

8. Repeat Steps 5 and 6.

9. When the end play setting is correct, set one tang of the lock
washer into a slot in the lock nut.

10. Inspect and replace the O-ring on the oil seal holder and on the
end cap, if damaged. Replace the oil seals.

11. Reinstall the oil seal holder, oil seal, and retaining ring (see Figure
5.4 - KZ- and KT-Bearing Frame Overhaul) making sure the seal
and O-ring are lubricated with grease or oil.

12. Install the motor adapter on the motor end of the bearing frame.
The oil seal rubber must be lubricated with grease or oil and the
shaft key must be covered to protect the oil seal from damage.

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TO PREVENT OIL LEAKAGE, DO NOT TO DAMAGE THE SEAL LIP.

13. A thin metal sleeve placed over the end of the shaft will suffice.
The sleeve should be tapered on the end so the seal can be easily
slipped on the end. As an alternate, thin plastic tape, applied 1-1/
4 wrap at a time, can be used to cover the key way.

14. Install the four (4) 3/8-in. bolts and lock washers to secure the
bearing frame cap.

5.2.5.6 INSTALL LIQUID END AND REMOUNT PUMP


The steps are as follows:

1. Install the liquid end on the bearing frame (see 5.2.2.2 Installation
of Liquid End Assembly, Steps 1 - 5).

2. Mount the pump on the motor or other mounting position and


tighten the clamp on the discharge support.

3. Lubricate as indicated in 3.7 Lubricating The KZ-Bearing Frame


Pumps.

5.2.6 OIL SEAL REPLACEMENT


Oil leaking around the bearing frame shaft indicates oil seal #2 (see
Figure 5.4 - KZ- and KT-Bearing Frame Overhaul) is leaking.

Oil leaking from the ports in the bearing frame near the liquid end
indicates oil seal #1 is leaking.

5.2.6.1 REPLACEMENT OF OIL SEAL #2


The steps are as follows:

1. Remove the flexible coupling guard, if installed.

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2. Remove either the pump or the motor from the bedplate or other
mounting.

3. Remove the flexible coupling flange and key from the bearing
frame shaft.

4. Remove the four (4) bolts and lock washers that fasten the
adapter to the bearing frame. Separate the motor adapter from
the bearing frame.

5. Remove the oil seal from the motor adapter. Replace with a new
oil seal.

6. If damaged, replace the O-ring on the motor adapter.

7. To prevent damage to the oil seal from the shaft key way, cover
the key way in the shaft as described in 5.2.5.5 Check End Play of
KZ- and KT-Bearing Frames.. Apply grease or oil to the bearing
frame shaft.

8. Install the motor adapter onto the bearing frame. Care must be
taken not to damage the oil seal lip.

9. Reinstall the four (4) bolts and lock washers so it is flush with the
end of the shaft and remount the pump or motor as required.

10. Reinstall the coupling flange so it is flush with the end of the shaft
and remount the pump or motor as required.

11. Recheck the oil (see Figure 3.5 - Initial Cold Setting of Oil Level for
KZ-Bearing Frame Pumps).

5.2.6.2 REPLACEMENT OF OIL SEAL #1


The steps are as follows:

1. Remove the liquid end assembly from the bearing frame as


described in Section 5.2.2.1 Removal of Liquid End Assembly).

2. Remove retaining ring #1 (see Figure 5.4 - KZ- and KT-Bearing


Frame Overhaul).

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3. Remove the oil seal holder (see Figure 5.3 - Removal of


Mechanical Seal), which can be done as described in 5.2.5.2
Bearing Frame Overhaul Procedure, Step 4, or by making a simple
fixture as described in the following procedure:

a. Use two (2) 5/16-18NC bolts and a flat plate (not provided) to
bridge across the end of the bearing frame to pull out the seal
holder.

b. Drill two (2) holes, 3/8-in. (10 mm) diameter, through the flat
plate, spacing the holes 3.25-in. (82 mm) apart.

c. Insert two (2) 5/16-18UNC bolts through the plate and turn
them into the seal holder’s two (2) coupling nuts provided.
(Select bolt length as needed to engage coupling nuts).

d. Tighten the two (2) bolts uniformly to pull the seal holder out
straight.

4. Remove the oil seal from the seal holder and install a new oil seal.
The seal should be flush with the exterior side of the seal holder.

5. Reinstall the oil seal holder and retaining ring in the bearing
frame. Make sure the O-ring on the outside of the oil seal holder
and oil seal lip are lubricated before installing. If damaged,
replace the O-ring.

6. Install the liquid end and remount the pump (see 5.2.2.2
Installation of Liquid End Assembly, Step 4).

5.2.6.3 REPLACEMENT OF OIL CHAMBER BULKHEAD


The steps are as follows:

Removal

1. Remove liquid end. Disassemble the bearing frame (5.2.5.1


Disassembly of Pumps with KZ- and KT-Bearing Frames).

2. Remove the bearing frame vent.

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3. Using a long screwdriver or 3/8-in. diameter bar, knock out the


bulkhead.

• Access the bulkhead through the vent hole in the top of the
bearing frame.

Installation

1. Apply a gasket forming sealant to the outside diameter of the


new bulkhead.

2. Insert the bulkhead into the bearing frame with the lip outward
and press into place.

3. Assemble the bearing frame (see 5.2.5.4 Assembly of Pumps with


KZ- and KT-Bearing Frames).

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SECTION 6
MATERIAL SAFETY DATA
SHEETS
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SYNTHI11C (III.
Royal Purple, Inc.
Material Safety Data Sheet
I. Product Name: Synfllme Date IssuedlRevlsed: Apr i I 22. 20 I I
Chemical Family: Synthetic based lubricating oil
Use: Lubricant and corrosion Inhibitor
Manufacturer: Royal Purple. Inc.
Address: I Royal Purple Lane. Porter. Texas 77365 USA
Phone: 281-354-8600 Emergency Phone: 281-354-8600 Fax: 281-354-7600
24 Hour Emergency Numbers USA:800-424-9300 International: 703-527-3887 (collect calls accepted)

11_ Components:
• Base Oil (synthetic) - Synthetic additives with Iso-paraffinic diluents.
• The precise composition of this oil is proprietary. A more complete disclosure will be provided to a physician or
nurse in the event of a medical emergency .
• All components of this product arc listed on the U. S. TSCA inventory.
• This product contains no hazardous substances within the definition of OSHA Regulation 29 CFR 19 10 . 1200.
• Royal Purple certifies that this product has been evaluated for RCRA characteristics and does not meet the criteria of
a hazardous waste if discarded in its purchased form .

III. Main Hazards I Health Effects:


Eyes: May cause irritation.
Inhalation: Oil mist may line breathing passages with oil making breathing difficult.
Ingestion: May cause diarrhea .
Skin: May irritate the skin after prolonged periods of contact.

IV. First Aid:


Eyes: Flush with water until all residual material is gone . Jr irritation persists. seek medical help .
Inhalation: Clear air passage . If respiratory difficulty continues, seek medical help.
Ingestion: Wash out mouth immediately . Do not induce vomiting. Consult physician .
Skin: Wash thoroughly with hand cleanser. followed by soap and water. Contaminated clothing should be dry cleaned
before reuse .

V. Extinguishing Media:
Suitable: Foam. dry powder. Halon*. carbon dioxide. sand. earth and water mist.
Unsuitable: Water jet .
Protective Equlpmentfor Fire Fighting: Self-contained breath i ng apparatus .

VI. Accidental Release Measures:


Personal Precautions: Wear gloves and protective overalls .
Environmental Precautions: Do not allow it to enter drains .
Spillage: Contain spill and keep from entering waterways. Absorb on porous material. Large quantitie s can be pumped.

VII. Handling and Storage:


Handling: No special handling precautions necessary .
Storage: Do not store at elevated temperatures.

VIII. Exposure Control I Personal Protection:


Respiratory Protection: Hydrocarbon absorbing respirator if misting .
Hand Protection: Oil-proof gloves for hypersensitive persons.
Eye Protection: Glasses . if applied to parts in motion.
Body Protection: Overalls.

IX. Physical and Chemical Properties: Evaporation Rate (Butyl Acetate) : Neglisible
Physical State: Liquid Vapor Pressure (kPa): <0 . 1
Color: Purple Percent Volatiles : None
Odor: Lube Oil Density (g/cm') : >0.83
pH : Neutral Flammability: Not flammable at amb i ent temp.
Boilinl Range I Point OF eC) : 650-800 (343-427) OAR Value : UN
Pour Point OF eC): <-30 «-34) Ox id izing Properties: None
Flub PoiDt (COC) OF (OC) : >440 (227) Water Solubility : Insoluble
Autoisnition Temperature OF eC): >600 (>315) Vapor Density: Greater than air
Product Name: Synfllm®
X. Stability and Reactivity:
Stability: Chemically st able under normal conditions. No photorcactive agents.
Conditions to Avoid: Powerful sources of ignition and ell\reme temperatures.
Materials to Avoid: Strong inorganic and organic acids. ollidizing agents.
Hazardous Decomposition Products: Burning generates smoke. airborne soot. hydrocarbons and ollides of carbon . sulfur
and nitrogen . Residue mainly comprised of soot and mineral oxides .

XI. Toxicological Information: Califomla Prop 65: N I A


Acute Toxicity: Not known Carcinogen: NTP: N 0
Irritancy-Skin: V e r y mil d IARC: No
Skin Sensitization: Not known OSHA: No
Subacute 1 Sub-chronlc Toxicity: Not known EC Classification (67 1548 I EEC): No
Genotoxlclty: None known LD-50: >2000mg/kg . utrapolated from component data
Chronic Toxicity: None know n LC-50: Not applicable

XII. Ecological Information:


Possible Effects: When released into the environment. adsorption to sediment and soil will be the predominant
behavior.
Behavior: Relatively well behaved. Bioaccumulation potential nil.
Environmental Fate: Due to its fluid nature and specific gravity. this product will float or spread across water making it
a nuisance contam i nant. It is not thought to be tOllic to marine or land organisms.

XIII. Waste and Container Disposal:


Waste Disposal: Consider recycling. This product. as sold. does not meet the RCRA characteristics of a hazardous
wRste. Under RCRA. it is the responsibility of the user. at the t ime of disposal. to determine whether the product meets
the RCRA criteria for hazardous wRste. Contact a waste d isposal company or local authority for adv ice.
Container Disposal: See waste disposal section listed above.

XIV. Transport Information: Air Transport (ICAO.IATA): Bulk Nonhazardous


DOT: Nonhazardous Sea Transport (IMO. IMDG): Bulk Nonhazardous
UN No.: N/A Road and Rail Transport (AD.R 1 RID): Bulk Nonhazardous
DOT: Nonhazardous

XV. Regulatory Information: CERCLA: Nonhazardous


Labeling Information: Nonc needed TSCA: All components are listed
EC Annex 1 Class.: N I A WHMIS (Canada): Not regulated
R Phrases: N I A Canadian DSL: All components are listed
SARA 311 1312: None 40 CFR Part 372 (SARA Section 313): N I A
S Phrases: S-3 keep cool. S-16 keep away from ignition RCRA Hazard Class: Nonhazardous
sources TSCA 12B Components: Non e
Ozone Depleting Chemicals: N I A

XVI. Other Information:

LEGEND
I. Identlflcallon of the Subalance I Preparation and Company
IL ComposJUon Infonnatlon on Ingredlentll NFPASYMBOL
IH. Hazardsldenllftcatlon FtRE

,~~.~
1\1. First AId MeaSUre5
V. Fire Flghlklg Measures
VI. AccIdental ReJeese Measures
VII. Handling and Storage
Signature: VIII. Exposure ConJroJ I PeIsonaI ProtedIon PERSONAl PROTECTION
INDEX
Prepared By: W . j. Ca rter. Ph.D. IX. Physical and ChemIcal Properties
X. StabIUty and Readlvlly
Date IssuedlRevised: April 22. 20 I I XI. ToIdccIogIcaIInIormaIIon HMISSYMBOL
As or iss ue da lc, Ihe iaro rmation conlai ned bere ln is AccuraU: a nd rc li·
XII. EccJcgJc:a1 bd'onnallon HEALTH 0
uble 10 Ihe bes l o r RO)'ol Pu rple', tnowled s c. Ro)'ol Pur ple d OCK nol XIIL V\Iaste DIsposaJ
FLAMMABILITY 1
wurrant ur , u.rontce i ls accuracy ur relhlb ilil )' Dn d sholl nc'II bc liuble XIV. Transport InfonnaUon
ror an )' Inll ur dama,c orisin" Qui or the Ul e: thereo f. It i. the u.c r·,
re'pon sibil i ly to . a' I If ~· itle lf tllat the inrorm • • ion oUored ror 1Is co.·
xv. Regulatory information REACTIVITY 0
slderal ioD I S sU Il.blc rt)r i ta particular UI C.
XVI. Other bI1cmI8llon PPI B
SECTION 7
SERVICE & SUPPORT
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GE Water & Process Technologies
Tonkaflo Pumps AS Series Operation & Maintenance Manual

7.1 INTRODUCTION
This section provides service information for the Tonkaflo Pumps AS
Series.

7.2 GE W&PT CONTACT INFORMATION


GE Power & Water

Water & Process Technologies

5951 Clearwater Drive

Minnetonka, MN 55343-8995

Phone: 952-933-2277

FAX: 952-933-0141

Toll Free: 1- (800) 848-1750.

EMAIL: GEWater.TechnicalSupport@ge.com.

7.2.1 ORDERING PARTS


To order parts, the following information is necessary:

1. Pump model number (see pump label).

2. Pump serial number (see pump label).

3. Other nameplate information such as operating temperature,


materials of construction, or material code and type of
mechanical seal.

4. Motor horsepower, motor frame size, and enclosure


specification.

Service & Support


October, 2012 7-1
GE Water & Process Technologies Tonkaflo Pumps AS Series
Operation & Maintenance Manual

5. Part name.

6. Part number.

7. Quantity desired.

8. Specific materials of construction, if any.

7.3 TONKAFLO SERVICE POLICY - LIQUID


ENDS
Section 5 - Maintenance Requirements of this manual was written to
assist customers in performing minor maintenance in the field on
Tonkaflo pumps. Proper maintenance will ensure longer pump life and
minimize down time.

Tonkaflo pumps are manufactured to make field repairs on the


mechanical seal a quick and easy process. Bearing frame overhauls may
be done by the customer, a local maintenance shop, or the factory. If
repair at the factory is desired, perform the following:

1. Call GE W&PT for a Return Goods Authorization (RGA) number.


See 7.4 Tonkaflo Pump Return Goods Authorization (RGA)
Procedure for details.

2. Send the complete pump, with or without motor, to the factory.

For motor problems, such as worn out motor bearings, it is


recommended that maintenance be done at a local motor repair shop.

For motor service, motors must be sent to the nearest authorized


motor service center for repair, replacement, and warranty
disposition.

Service & Support October, 2012


7-2
GE Water & Process Technologies
Tonkaflo Pumps AS Series Operation & Maintenance Manual

Field service of the liquid end, with the exception of mechanical seal
replacement, is not recommended.

• If a liquid end is damaged by running the pump dry, inadequate


flow, excessive deadheading, cavitation, or other reasons,
contact a Tonkaflo distributor certified for service or return the
pump with or without motor to the factory for repair.

• The pump has a oil lubricated bearing frame between the pump
liquid end and the motor. They are typically characterized by a
“KZ” or “KT” in the model number (e.g., AS9023KZ or AS40415KT).

• To return an oil lubricated bearing frame pump to the factory, GE


W&PT requires the whole unit (pump liquid end, bearing frame,
and motor adapter) less the motor and flexible coupling pieces. If
the motor adapter is not returned, GE W&PT will connect a new
one to the repaired pump liquid end/bearing frame and the client
will be billed for it.

• The original bearing frame is essential for the rebuilding of the


pump liquid end on the 9000, 14000, 225000, and 40000 Series
pumps based on the pump design (locked impellers). The pump
liquid end and bearing frame form a “matched set”. Also, a
bearing frame is required to test the pump.

• If a new bearing frame needs to be attached to the pump liquid


end in order to perform a test, it will be shipped with the repaired
liquid end of the pump and the client will also be billed for it.

7.4 TONKAFLO PUMP RETURN GOODS


AUTHORIZATION (RGA) PROCEDURE
If it is necessary to return goods for repair, warranty evaluation and/or
credit:

Service & Support


October, 2012 7-3
GE Water & Process Technologies Tonkaflo Pumps AS Series
Operation & Maintenance Manual

1. Contact GE W&PT’s Customer Service Center. See 7.2 GE W&PT


Contact Information.

2. When contacting GE W&PT’s Customer Service Center, have the


original sales order or invoice available.

• A GE W&PT Customer Service representative will provide


instructions and a Return Goods Authorization (RGA) number
which needs to be clearly written on the outside of the box used
to ship return materials.

• All equipment must be shipped to GE W&PT with the freight


prepaid by the customer.

• Call the Customer Service Center with any questions or issues


concerning freight claims and a representative will discuss
your situation.

• All materials to be returned must be rendered into a non-


hazardous condition prior to shipping.

• Returns can be handle in either of the following ways:

a. Send in the pump for repair and return.

b. Purchase a new pump and, when desired, send the defective


pump to the factory for repair and return.

7.5 MOTOR WARRANTY


Motors must be sent to the nearest authorized motor service center for
repair, replacement, and warranty disposition.

7.5.1 IN-WARRANTY PUMP FAILURE


• Return the defective pump to the factory for repair on an RGA
within fifteen (15) days from RGA issue date. GE W&PT absorbs
the cost of repair.

Service & Support October, 2012


7-4
GE Water & Process Technologies
Tonkaflo Pumps AS Series Operation & Maintenance Manual

• The repaired pump will be returned and is under warranty for the
remainder of the original warranty period or three (3) months,
whichever is longer.

• GE will not restock or issue return credit against a new, custom-


built, pump purchase regardless of the warranty status of the
failed pump.

7.5.2 OUT-OF-WARRANTY PUMP FAILURE


• Return the pump on an RGA for repair.

• The pump will be repaired and repair charges invoiced to the


customer.

• The warranty on repairs is three (3) months.

7.5.3 SHIPPING CHARGES

7.5.3.1 IN-WARRANTY
• The Customer pays for shipment to GE W&PT.

• GE W&PT pays one way surface freight return to customer.

7.5.3.2 OUT-OF-WARRANTY WHEN NEW PUMP IS PURCHASED


• The Customer pays all shipping charges.

Service & Support


October, 2012 7-5
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SECTION 8
RECOMMENDED SPARE PARTS
LIST
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intentionally left blank
Standard Model Parts List - 1125317

Item # Part Description Part # Item # Part Description Part #


1 Clamp, Pump Shell Support 24 Nut, Lock 1113768
AS9000 & AS14000 1114375 25 Discharge Support Assembly
AS22500 1122957 (With #s 23 & 24, Center line)
AS40000 1125359 6.25, AS9000/14000/ 225000 1125426
2 Liquid End Assembly * 7.00, AS9000/14000/ 225000 1125427
3 O-ring, Buna-N, -225 1114284 7.00, AS40000 1125168
4 Machine Bolt, 3/8-16 x 1/1/4-inch 1110984 8.00, 9.00, AS9000/14000/ 225000 1120600
5 Lock washer, 3/8-inch 1110012 8.00, 9.00, AS40000 1125169
6 Seal Holder 1120341 26 Plug, 1/4 NPT SS, 316 1115055
7 Shaft Key, 1/4- x 1-1/2-inch 1120445 27 Mechanical Seal:
8 Retaining Ring, N5000-433 1114280 Standard - Type 21, EPDM, 200 1122186
9 O-ring, Viton, -244 1113998 psi (13.8 bar), ceramic seal,
10 Bearing Frame Assembly AS40000
(All include Motor Adapter): High-Pressure - Type 1, EPDM, 1201945
KZA/KZB 1125246 400 psi (27.6 bar), AS40000
KZC 1125247 Standard - Type 21, Buna, 1121167
KZE 1125248 200 psi (13.8 bar), ceramic seal
KZF 1125366 High-Pressure - Type 1,Buna, 1116127
KTE 1225462 300 psi (20.7 bar), ceramic seal
KTF 1225429 High-Pressure - Type-1, Buna, 1114326
11 Vent/Breather 1114851 300 psi (20.7 bar), Ni resist seal
12 Roller Bearing, Cup & Cone 1120603 High-Pressure - Type 1, 400 psi 1115090
13 Lock Washer 1114282 (27.6 bar), tungsten carbide seal
14 Tanged Washer 1114283 28 Set Screw, Bearing Frame 1113769
15 Lock Nut, Left Hand Thread 1115975 29 Oil Seal Bearing Frame 1121049
16 Bearing Frame Shaft 1120348 30 Oil Seal Holder Assembly 1120723
17 Coupling Flange, Pump: 31 Retaining Ring 5100-187 1113999
Size 6, 1-5/8-inch bore 1114333 32 Washer, Bearing Frame 1120379
Size 7, 1-5/8-inch bore 1114334 33 Bolt, 1/2 x 13NC Low Profile 1114379
Size 8 1114335 34 Shim Bearing Frame 1120361
Size 9 1115177 35 Oil Sight Gauge 1225967
18 Coupling Sleeve: 36 Plug, 3/8 NPT 1122036
Size 6 1120306 37 Oil Chamber Bulkhead 1123792
Size 7 1121702 38 O-ring, -249 1121063
Size 8 1125111 39 Oil Seal, Motor Adapter 1113996
Size 9 1125112 40 Lock Washer, 3/8-inch 1110012
19 Key, Coupling Flange 1120444 41 Bolt, 3/8-16NC x 1-inch 1112048
20 Bolt, 1/2-13 NC x 1.25 1113973 42 Motor Adapter, Painted, KA/KB 1123382
Bolt, 5/8-11 NC x 1.25 1125103 Motor Adapter, Painted, KC 1123383
21 Lock Washer, 1/2-inch 1113104 Motor Adapter, Painted, KE 1123384
Lock Washer, 5/8-inch 1111650 Motor Adapter, Painted, KF 1125365
22 Coupling Flange, Motor: 43 Oiler, Cup & Globe 1114476
Size 6, 1-5/8-inch bore 1114333 44 Oiler Nipple, Close 1/4NPT 1110202
Size 7, 1-5/8-inch bore 1114334 45 Oiler Elbow, 3/8 NPT x 1/4 NPT 1121976
Size 8, 1-5/8-inch bore 1114335 46 Oiler Nipple, 3/8 NPT x 3-1/2-inch 1122025
Size 8, 1-7/8-inch bore 1114336
Size 9, 1-5/8-inch bore 1115178
23 Bolt, 5/16-18NC x 1/2-inch 1110471
Pump Cutaway Drawing – Replacement Parts (Refer to Standard Model Parts List)
Pump Accessories - 1125317

Part Description Part #


Retaining Ring Pliers for K Mechanical Seal Retaining Ring 1121717
Set Screw for Pump Shaft for D-, E-, G-, H, and K-Bearing Frames 1113769
Allen Wrench, 3/16-inch, for Set Screw P/N 1113679 1113770
Pump Discharge Screen (3-inch Victaulic) 1120501
Royal Purple Synfilm 68, synthetic oil:
1 Gallon 3097881
Anti-Seize Thread Compound:
16 ounce Can 1120110
10 ounce Tube 1112970
Carbon Bearing, AS9000, AS14000, and AS22500 Pumps 1120386
Carbon Bearing, AS40000 Pumps 1125327
Center Housing Tool, AS9000, AS14000, and AS22500 Pumps 1120780
Discharge Housing Tool, AS9000, AS14000, and AS22500 Pumps 1120781
Discharge Housing Tool, AS40000 1123153

ALL STAGE PARTS - FIELD REPAIR NOT RECOMMENDED


Part Description Part #
Mechanical Seal Replacement Kit

0 - 200 psi (13.8 bar), Type 21 Ceramic, EPDM 1238487


0 - 200 psi (13.8 bar), Type 21 Ceramic, BUNA 1121177
0 - 300 psi (20.7 bar), Type 11 Ceramic, BUNA 1120606
0 - 300 psi (20.7 bar), Type 1 Ni-Resist, BUNA 1120607
0 - 400 psi (27.6), Type 1 Tungsten Carbide, BUNA 1120608
0 - 400 psi (27.6), Type 1 Tungsten Carbide, EPDM 1238488

Victaulic Adapters

3-inch Victaulic x 3-inch MNPT 304SS 1120589


3-inch Victaulic x 3-inch MNPT 316SS 1120590
3-inch Victaulic x 2-inch FNPT 304SS 1120586
3-inch Victaulic x 2-inch FNPT 316SS 1120587
3-inch Victaulic x 1-1/2--inch FNPT 304SS 1120588
4-inch Victaulic x 4-inch MNPT 304SS 1122066
4-inch Victaulic x 4-inch MNPT 316SS 1122067
Victaulic Coupling, 3-inch, Style, Buna-N 1114373
Victaulic Coupling, 4-inch, Style, Buna-N 1115161
Victaulic Coupling, 6-inch, Style, Buna-N 1151628

Coupling Guard

KA/KB Coupling Guard Kit 1239456


KC Coupling Guard Kit 1239455
KE/KF Coupling Guard Kit 1231322
Recommended Spare Parts - 1125317

Spare Parts for Mechanical Seal Replacement and General Bearing

Part Description Part # Quantity

Installation, Operation, and Maintenance Manual for AS9000,


AS14000, AS22500, and AS40000 Series High-Pressure Pumps with
KZ and KT Bearing Frames 1125317 1

1-inch, Type 21, BF50 1C1-316SS Mechanical Seal Kit. Inlet Pressure
0 - 200 psig (13.8 barg) 1121177 1

1-inch, Type 21, O28F50 1C1-316SS, Mechanical Seal Kit. Inlet


Pressure 0 - 200 psig (0 - 13.8 barg) for AS40000 Pump Only 1238487 1

Royal Purple Synfilm 68, Synthetic Oil 3097881 2

Complete Set of Bearing Frame Replacement Parts

Part Description Part # Quantity


Bearing Frame Oil Seal, Motor Side (replaces 1113997) 1121049 1
Bearing Frame Oil Seal, Pump Side 1113996 1
O-ring for Bearing Frame 1113988 1
O-ring for Motor Adapter 1121063 1
Bearing Cup and Cone 1120603 2
Retaining Ring for Bearing Frame Housing 1114280 1
Retaining Ring for Bearing Frame Shaft 1113999 1
Lock Nut - Left Hand Thread 1115975 1
Lock Washer, Flat with Tag 1114282 1
Multi-tanged Washer 1114283 1
Bearing Frame Shaft - Left-hand Thread 1120348 1
Bearing Frame Shaft Bolt Shims 1120361 3
Painted Bearing Frame Housing 1123381 1
Bearing Frame Shaft Washer 1120379 1
Bearing Frame Shaft Bolt 1114379 1
Vent/Breather 1114851 1
Bearing Frame Shaft Set Screw Cone Point 1113769 1
Oil Sight Gauge 1225967 1
Oil Drain Plug, 3/8-inch 1122036 3
Oil Seal Holder Assembly (without Oil Seal, P/N 1113996) 1120723
Oiler, Cup and Globe Assembly 1114476 1
Oiler, Nipple, Close, 1/4 NPT 1110202 1
Oiler, Elbow, 3/8 NPT x 1/4 NPT 1121976 1
Oiler, Nipple, 3/8 NPT x 3-1/2-inch 1122025 1
Coupling Flanges and Sleeve: Refer to Coupling Size in the
Standard Model Parts List * **
Coupling Key Bearing Frame 1120444 1
Pump Shaft Key 1120445 1
Machine Bolts, 5/16 x 18NC x 2-1/2-inch long U.S. Thread
(for Oil Seal Holder Removal) 1116595 2

* Refer to Standard Model Parts List for Part Numbers


** Quantity of two (2) coupling flanges, quantity of one (1) coupling sleeve
For more information call 952-933-2277 or 800-848-1750 in the U.S., or visit www.gewater.com.

North American Sales Euro/Africa Sales Asia/Pacific Sales


5951 Clearwater Drive 230 rue Robert Schurman 1044/8 SOI 44/2
Minnetonka, MN ZA des Uselles Sukhumvit Road Parkanog
55343-8995 77350 Le Mée sur Seine Bangkok 10110
USA FRANCE THAILAND
(952) 933-2277 Phone +33 1 64 10 2000 Phone + 66 2 38 14213 Phone
(952) 933-0141 Fax +33 1 64 10 3747 Fax + 66 2 39 18183 Fax

© 2012, General Electric Company. All rights reserved.


P/N 1125317 Rev. C