Yidrasfal INSTRUCTION MANUAL FOR HIDROSTAL - PUMPS Fle SABAPMITITELBLPUS“Yitradtal Hidrostal AG Gigering 27 CH - 8213 Neunkirch ‘Switzerland Tel: +41 52 687 06 74 Mail: shari. muggli@hidrostal.ch 4 pos Pumpe-00016820 Beating frame pump E125-HO3R + EDM1X-M160Q FFT Motor date: 15KW 41500 Umin-1/ 50 He IEC 160 without speed regulation nsielletion: ‘horizontally Weights: Hydraullo Bosring Frame Serial No. 230709 Instruction Manual 94-BA 6030 94-BA 6039 94-BA 5086 Language: Englisch Instruction Manual No. 12020683 / 10 27.10.2014 Deiivery address Eekels Pompen B.V. Koopfiedenweg 25 NL - 2991 In Barendrecht Netherlands 108.00 kg 61.0049Yfidrastal SECTIONAL DRAWINGS Q-HYDRAULIC E080 -L500 REGULABLE MAT. CODE 1 -5R 49 t an utr 400 434 405-4 et eae “2 409 i 433 420 : 4B tf 442 ! 406 401 4 ar 422 : 48 ee a | Noe fan 431 PaRT| DESCRIPTION MATERIALS OF CONSTRUCTION aR 2 aR aR “400 | VOLUTE CASING GREY CAST IRON STAINLESS STEEL AS “oT | MAPELLER, NODULAR TRON STANCES STEEL | STAINLESS STEEL AA JOR DUPLEX STEEL 405 | INSPECTION HOLE GREY CAST IROW [STAINLESS STEEL AT 406] O-RING NITRILE 408 | WEAR RING GREY CAST IRON HIDRO HARD [STAINLESS STEEL Ad 409 [O-RING NITRILE ai | sams: STEEL [STAINLESS STEEL As 413 | ADJUSTING BOLT ‘STAINLESS STEEL Ad 415 | IMPELLER BOLT RUSTLESS STEEL STAINLESS STEEL AS 416_ | SUCTION CASING GREY CAST IRON [STAINLESS STEEL Ad 417_| FASTENING SET RUSTLESS STEEL ISTAINLESS STEEL Ad 419_| FASTENING SET RUSTLESS STEEL [STAINLESS STEEL Ad 420 _| FASTENING SET RUSTLESS STEEL [STAINLESS STEEL Ad azi_[ LINER GREY CAST IRON HIDRO HARD [STAINLESS STEEL Aa 422_| REGULATING NUT STAINLESS STEEL AS 42a | DISTANCE BUSH STEEL [STAINLESS STEEL Ad 423 | PLUG STEEL [STAINLESS STEEL AG 424 | PLUG STEEL [STAINLESS STEEL Ad 400 ORING NITRILE ast | ORING NITRILE ‘psnonsndeutgen vreaten ‘iouatranrs bette nak changes vou eh por ot, iowa sn vee out ant se Sagar tocar File: QE_DATA Pee a ceertaiateeseren | NO.: _ 90-TU 4150E// SECTIONAL DRAWING SCHNITIZEICHNUNG yyy x_/1g9 Hfidrasta FLEXIBLE, COUPLED BEARING FRAME PLEX, GEKUPPEL TE LAGERSTURL =/180 Witt HECK SEAL "A NEC HT 129 —— B4 —__ 5363—___ 516 ——___ 545 ——— 552a 527 — 5tla—— EE Bi cere BI 6 erect CEE TO eet ™ Q-HYDRAULIK K-HYORAULIK PARTS LIST ‘STUCKLISTE 400 Bearing housing Lagergehtuse 504 Oi chamber casing Getkammergehduse 101 Motor support Motortateme 507 Mech, seal plate/ mech. Dichtplatte/ 103 Bearing cap Lagerdecket Backcover Dichtrei 40% Spacer ring SMitzscheibe Sita Back cone ‘O-type’ —Rickkanus ‘Q-Type’ 106 Spacer ring Distanzeing Sto Back plate ’K-type’ — Rlickplatte ‘K-Type’ 110 Shaft Welle 515 Mech, seal P. Gleifringdlchtung P.S. tM Shaft stud Wellenzapfen 516 Mech, seal M Gleitringdichtung MS. 114 Coupling key eit zu Kupplung 527 O-ring 0-Ring 121 Bearings Lager 534 Fastening set Befestigungssatz 126 Lock nut for shaft Wellenmutter 536 Plug with gasket Stopfen mit Dichtring 29 V-ring v-Ring 565. Snap ring Seegerring ‘BI Greasing plug Stooten mit Dichtring 546 Snap ring Seegerring with gasket ur Schmierstelle 549 Oil sight glass Oetschauglas 386 Lubricant Stopfen 552 Plug Stopfen rain plug Tar Schniernittetablass 556 Eye bolt Ringschraube 85 Fastening set Bofestigungssatz 576. Shims Unteriagen ‘86 Fastening set Befestigungssatz for 507-511 zu 507-51 146 O-ring O-Ring 597 Nameplate Typenschitd 48 O-ring O-Ring 605 Socket set screw Gewindestitt 165. Impeller flange Laufradzufnatme 625. Fastening set Befestigungssatz 19% O-ring 0-Ring 631 Coupling MS. Kupptung MS. 196 Fastening set Bofestigungssatz 632 Coupling P.S. Kopplung P.S. 209 O-ring O-Ring 634 Rubber parts Gurmitet [iraen by/Bearh Dal. VS. 2 C6020 ee Sie oie byte ibe ve tatzore| NO: 98-S5865arf | SECTIONAL DRAWING SHORT AND FLDX. COUPLED BEARNG FRAME GENERAL ASSEMBLY INSTRUCTION FOR MOUNTING OF BEARINGS WITH DOUBLE-O-ARRANGEMENT - TO BE USED UP FROM OCTOBER 2005 - FOR EXACT ASSEMBLY, THE RELEVANT SINGLE] SECTIONAL DRAWINGS MUST BE USED ! ALLGEMEINE MONTAGE-ANWEISUNG FUR LAGERANORONUNG 2 - FACH ‘0° - ZU VERWENDEN AB OKTOBER 2005 - \FUR GENAUE MONTAGE SIND DIE ENTSPRECHENDEN) EINZELSCHNITTBILDER ZU VERWENDEN ! z Ne 110 rT 7ELz 100 NAB" | NSS Sr 5 as ' eee |e I SCETCH: SCETCH: NEW A OLD BEARING oh DOUBLE-0- iy ‘ARRANGEMENT i). 7S AS ARRANGEMENT fy | (unfit Sept. 2005) FF (SEE ABOVE) “4 4 - SCHEMA: aN, ‘SCHEMA: ALTE LAGER- ‘S iB NEUE 7 hd ANORONUNG ao cA DOPPEL-0- WL (bis Sept. 2005) iB ANORONUNG . - oe (SIEHE OBEN) 4 Vv 7 a bya Dal VES aa ooraved by Game Oat Ve oko | NO + is sen |No. 12020683 / 10 27.10.2014 Pump: Serial No. £125-HO3R + EDM1X-M160Q 230709 Parts list Part No. Desoription Qty, [unit 100850 Bearing housing “pes 7102089 Motor bracket “pes 700842 Bearing cap 1 pes 121484 Support disc pes 01734 ‘Spacer tng pee 102876 Shatt “pes 120160 Shaft key “pes 120803 Roller bearing “pos 120601 Shaft nut ‘pes 116882 VRing Tes 7119067 ‘Copper Sealng rng = Tes "120582 Piug "720528, Phug "720328 Plug 7119038 Slug "T19994 ‘Spring washer "720288 Hexagon nut 7118964 ‘Spring washer "20081 ‘Cheese fead screw 10858 O-Ring 716525 ‘O-Ring "134008 OF 139712 116537 O-Ring ra0298 Hexagon nut 120540 Flat washer 119820 Stud 719900. Spring washer Bes 6852 O-Ring ‘pes 08686 Pump Casing “pes 105835 impel ‘pes 107688 inspection cover pes [76852 ToRing Toes 108762 Wear rng Tes 716800 ‘O-Ring Tee 36292 ‘Shim B pos 119870 Stud 3 pes 119088 Spring washer Ses 20086 Hexagon uf 3 pos 0772 impetor bok Ter "108930 Suction casing Eee pes 719864 Stud pos 75904 Spring washer pos 120298 Hxagon nut Spee 130549 Fiat washer oo fioeat Stud 3 pe 20208 Hexagon nt 8 ps 20518 Ribbed washer Bes 20 | F780 Sud 2 pes [420_—| 119004 ~~~ Spung washer Zs fa20_— | 20200 Hexagon nt a 2 pes a2 | 09998 tine ‘pos az | a0 Distance bash Ses [axa [vv0n26 Regulating nut a 3 pos 25 — | 120828 Pug 1905 jana [20328 Pug “pes rao — [76889 ‘ORing pee raat [116696 O-Ring pes soa | 135296 | Oi chamber caaing a pes ‘507 [401482 te 4 pes 14-QF 8311 Page 1 of 2Pump: E125-HO3R + EDM1X-M160Q Parts list 708 [Part No. Sit [101997 516 | 116247 16557 534 | 119059 "119900 534 [120208 36a _| 120502 7110067 5360 _| 120502 119067 545 [121203 195775 720328, "120538, 120353, 14-OF 8311 iption Back plate Mechanical seal ‘ORI ‘Sud ring washer Hexagon nut Plug | Copper Sealing tng per Seng rg Circlip Oilfeval lass Plug Piug Eye-bott ‘Shim ‘Geubscrow ‘Spring washer Hexagon nut Hexagon bolt Flat washer Coupling PS. Coupling PS. ‘Coupling Paint No. 12020683 / 10 27.10.2014 Serial No. 230709 Page 2 of 2idrostal Hidrostal AG, Gigering 27, CH ~ 8213 Neunkirch, Tel: +41 52.687 06 87 Fax: +41 52 681 20 84 www hidrostal.ch [2CG-Declaration of Conformity We deciare in exclusive responsibilty that the construction of the Hidrostal Screw Centrifugal Pumps to which this, declaration relates are in conformity with the following health and safety standards: EC-Directve: 2008/42/EC Machinery directive 2006/95/EC Electrical Apparatus for use within specified voltage limitations. Low Voltage Directive (LVD) 2004/1 08/EC Electromagnetic compatibilly EMC Hydraulic-sizes: Asset Bastian Gratis Doct Beatin Fon Assembled with the units "Three-phase current motor" Bovey Barney -T. (002... 003, 050,090, Maree WN 1008. -y OOM ay OM ry OTA ny O20. O80. 130.20, 190.2, 300. BO2. =. BOB... or the units “Bearing frame" mechanical seal BM... -CM.=.. DM. LM ance MM... XM. EM. or the units "Bearing frame" stuffing box seal 1 DZ... BS... C8. Is.~.., LS... MS.-..., XS. HS. ‘Authorized person for compiling the technical fite: Carmen Baur Neunkirch, 07.04.2010 ee fie bay (eee — Hans-Peter Haas Urs Eckman Leiter Tech. Buro, CTO Quality manager Rev. 6; 10 Reg No: 08 ~ QF 7416Ea ZAOMSIOS\Urs Eckmann\Zertfikale\EG Kon alg08.OF 7418Ea CE Kon englsch_rev8,10.doc 07.04.2010 ueit / INSTRUCTION MANUAL Teen deat GENERAL USE Dat.: 29.11.06 No: 94-BA 5030E/1e File: ALLG_E TABLE OF CONTENTS Part 0 0. General directions 0.1 General safety directions 0.1.1 Safety and warning directions Part | 1.0 Pump code explanation 14 Delivery 4.1.4 Reception of pump unit 1.1.2 Nameplate data 1.1.3 Storage 1.2 Installation 4.2.1. Mounting 13 Piping 4.3.1 Suction piping 1.3.2 Sizing of suction pipework 4.3.3 Discharge piping 4.3.4 Connection of piping 14 Special applications 15 Use in potentially explosive atmosphere 16 Operating interruptionYi INSTRUCTION MANUAL fidrostal GENERAL USE Dat.: 29.11.06 No: _94-BA 5030E/3d File: ALLG_E 4.0 PUMP CODE EXPLANATION ‘The pump-code is a combination of joined-together in series construction groups. The “plus sign" is the separation between these groups, and the “dash” is the separation between general and specific description of each construction group, PUMP CODE CONSTRUCTION GROUPS Group 4 Group 2 Group 3 EXAMPLES: FIOKHDIR = + FE@S4-MINGK = + ~——N3B4-10 DOKQ-LOIKE = + =:DNXT2MXEQ 6+ = X2B1-15 F100-Lot + FESZ7-CNEK = + N2E1-10 A2QR2-CC3 + ANI-10 F150-S03R + FFM10-XM.Q HOGF-Mo1 + HRst0-L E0SK-MOt + EDMIF-MIM.K Hydraulic Hidrostal-Motor Cable Set or Bearing Frame 44 DELIVERY HIDROSTAL will not assume responsibilty for damage to the pump that has been caused due to not § following instructions in this manual, nor for consequential damages of any kind. 444 RECEPTION OF PUMP UNIT Inspect the shipment for shortages or damage, Report any discrepancies to the carrier, note them on the shipping documents and sign them with date together with the carrier. 44.2 NAMEPLATE DATA Each pump is equipped with a nameplate showing all technical data of the pump. Itis essential to give the complete data when enquiring about parts or service. ‘An explanation of the meaning of this code can be found under Section 1.0 "Pump Code Explanation’. 44.3 STORAGE Ifthe unit is not to be installed immediately, note: = Store in a dry and clean place without extreme changes in temperature (storage room temperature - 10° to +40°C (14° to 104°F). - Rotate the shaft by turning the impeller once every two weeks to ensure positive coating on the fubri- cated surfaces and to prevent sticking of surfaces due to rust or oxidation = Do not store in a location where the pump would be subject to vibrations, otherwise brinelling of the bearings could occur.dr / INSTRUCTION MANUAL freee sere GENERAL USE Dat.: 29.11.06 No: _94-BA 5030E/5d File: ALLG_E MO Lo air pocket a Fig.1 Fig. 2 air pocket Fig. 3 Fig. 4 Unusual suction conditions such as high liquid temperature, altitude above sea level and high specific FLEXIBLE-DIRECT-COUPLED PUMPS, MECH. SEAL Dat; 02.12.05 No: _94-BA 5086E/ 6f File: Q_FLEX_E Oo 2.6 MAINTENANCE AND SERVICE 264 GENERAL Exe) Pay attention othe clovartinottons Before doing any work on the pump unit, switch off main isolator switch and remove fuses from panel, The following checks canbe done inthe field. When arepairisindicated, send the pump unittothe nearest authorized Hidrostal service station, 26.2 VISUAL CHECKS OF PUMP UNIT = Check pump and moter for possible mechanical damage. = Ifpump volume or pressure are not acceptable, check impeller clearance (see manual for hydraulic) ~ Check overload relay, fuses and time relays (if any) for correct setting. ~ Check correct function of level control = Annual check for wear of the coupling. 2.63 SERVICE CONNECTIONS The service connections that are built into all pumps as standard are listed below. Please refer to Fig. 3 and sectional drawings. '552a/552b Seal Flushing Connections ‘Alternatively or even in addition to the function described in section 2.1, this connection may be used to manually bleed the air from the casing prior to start-up, ifthere is no other place for air to escape through the discherge piping. In most cases the connection 852b will be closed and flushing water mixes with product pumped. in cases where the solids accumulate, could form lumps, or be fibrous flushing out via {552b would be the preferred solution. Connection 552b also permits complete draining of product from horizontal bearing frames if required. 536a ‘Connection “OIL IN" Opening to refil seal il 538b Connection "OIL OUT" Opening to remove seal oil DIRECTION: SEE SECTION DESCRIBING "OIL CHECKING" (2.6.4) AND “OIL CHANGE" (2.6.5) FOR DETAILED INFORMATION. 431 Greasing point "G1" 6 ; By Determining thickness of shims (411) (Fig.3): All types, oxcopt for BOBQ/BU6S: Measure the existing gap ‘O’ between drive unit and casing in several places and calculate the average value. Add approx. 0.5 - 1.0mm to this value. The result is the required thickness of the shims (411) required to obtain the clearance °C’ (Table 2). ‘Types BOBQYBOES: Measure gap between drive unit and suction cover in several places and calculate the average Value. Add approx. 0.5 - 1.0mm to this value. The result is the required thickness of the spacing ring (414) required to obtain the clearance ‘C’ (Table 2). Raise drive unit and at every fastener (419; 4417 at B0BG/B06S) place shims (411; 414 at BOBQ/B065) of the ‘calculated thickness between drive unit and casing (between casing and suction cover at 80BQ/B065). Lower drive unit. Tighten fasteners (419 or 417). Measure impoller clearance in accordance with section 3.2.2. If the existing clearance "C" deviates from value given in Table 2: A) With regular clearance, loosen fastenings (417 ‘r 419) again and change thickness of shims (411 or 414) until the desired clearance is reached. Use washers of uniform thickness, or U-shaped shims. These must be placed under each fastener (419). Thin shims may be a single plece of stee! wire (diameter = calculated thickness), wrapped all the way around drive unit under the studs (419); ends can be bent outward around last studs (419) to avoid overlapping. Tightening all fasteners (419 or 417). Or B) Wear exists (loo large or uneven clearance, itis recommended to dismantle the pump and to check the wearing parts; see Section 3.3). 3.2.5 CLEARANCE ADJUSTMENT IMPELLER - BACK CONE OR BACK COVER ‘Clearance ‘8 betwen impeller (401) and back-cone (511) or back-cover (507) must be held in a maximally stnail way (Table 2) in order to complicate entry of fuzz or solid matters into the seal room. Because of abrasive ‘medium the clearance with time can enlarge itself. With new assembly of impeller, clearance 'B’ can get too small or too large (impeller could touch at back-cone / back-cover). Measuring of clearance ‘B’ with mounted impeller (401) as follows: Clamping back-cone with se'f-grip wrenches at seal plate (507). Insort fooler gauge in gap between impeller and back-cone or back-cover at several places and note the measured values. Compare smallest measured value with table 2. If clearance is too small, remove existing shim (576). If the clearance is too big, add shims until correct clearance is reached. Ejslohawn —Datunidae Name: 1507 2016 ay SoitaPage Svoniot 15 No.: 94-BA 6039ENc Q-Hydraulic.docx Gepalleppeoted Dolonddslo Nome: 73.0972014“fiidrastal INSTRUCTION MANUAL ~ Q-HYDRAULIC In some cases, impellers of hydraulic size M have an er 440a,b impeter tlange (165) installed on the pump shaft (Fig. 9). The exact configuration can be found in the corresponding technical documentation, Preparation: in order to loosen the Impeller bolt and remove tho impeller from the shafl, we recommend that the bearing frame — or motor-impeller unit ~ are brought Into a vrael positon vith tha mmpallarecing upwards. = // 4 Protective cap (497): In otder to protect the tensioner © | | jackbolts from dirt and wear, a protective cap (437) is Wslaled’ over tho Tensor (tem. Fy 8) Aer : Ca Tene nl eae Ae NY ee facto wih bot ekng compound). the potectve cap . ats (437) can be removed by hand. 433 7° : Se cies 3232 LOOSENING OF THE SUPERBOLT® Fae protoneoning system CAUTION! Before the fourteen individual MB jackbolts are loosened, the actual tightening torque should be ‘checked using a torque wrench against the tightening torque prescribed in Table 4. This prior check allows the correct previous installation to be confirmed and the existing application checked for its system stability, Should it unexpectedly be discovered that some jackbolts no longer have the full preload, we recommend following the procedure described in section 3.3.3.3 ‘Maintenance’, ‘CAUTION! Loosening demands strict observance ofthe instructions. The jackbolts must be unloaded in steps! ‘On no account may the individual jackbolts be loosened completely in one step; the other jackbolts would then have to carry the full oad and would be correspondingly more diffcul io loosen, Inextreme cases, the jackbolts Could be damaged and loosening would no longer be possible! Different loosening methods have to be applied, depending on the application temperature. This manual describes only the procedure for temperatures under 100°C. Instructions for applications at 100°C and h igher can be obtained from your Hidrostal dealer or from the manufacturing works. Preparation: Apply a litle penetrating oil before loosening, particularly if there are signs of rust Step 4 (Fig. 7 and 8): ‘Starting at jackbolt No. 1, loosen each jackbott in tum by roughly 1/4 ‘tum (ust braking loose is sufficient), working in a circle. After each of the jackbolts has been loosened slightly, jackbolt No. 1 willbe tight ‘again, but on a lower load level. Note: if several clamping elements have to bo loosened, 0.9. on several pumps, carry out step 1 on all the pumps before proceeding tostep 2. Step 2: In the 2nd step, repeat step 1 also forall tensioners, Stop 3: Repeat step 1 in a 3rd round, Step 4: Loosen the jackbolts completely; the tensioner can now be removed by hand. Note: Long stud screws (4182) expand more and may therefore require one or two more steps before they are loose. Ertoliown _-Dalumidte Name: 16072014 db SeieiPage 7 voniot 15 No.: 94-BA 5039ENc Q-Hydraulic.docx Goprtlapproved-Dalunfdoa Nome! 23.00.2044 c=~Yfidrastal —NSTRUCTION MANUAL - @-HYDRAULIC 3.3.5 REMOVE LINER FOR COCQ/DODQ AND C080/D100 / DO3H/DO3M/DO3U/DESHIDESM/DE3U / DOM/DO4UIDEAMIDE4U "NON REGULABLE™ (Fig. 10 und 11) ‘These pumps have a non-adjustablo liner (421) held in a fixed position inside a one-piece volute casing (400). Liner can bo pressed out ofthe casing from suction opening. oo on 0 a “0 Fig. 10: COCQ/DODQ/ DOsH Z i i bid DESH /DO4M/DEAM Fig. 11: C080 /DO3U / DE3U Bo4u/ DE4U/ D100 3.3.6 REMOVE SUCTION COVER FOR "NON-REGULABLE” PUMPS ig. 12+ 13) These pumps have a one-piece suction cover (402), which is bolted to the volute casing (400) by studs and nuts (417). Certain models may have a spacer ring (414) between mating surfaces of the suction cover and the volute casing, “os, POAT SHE | 4B ae ™~ 0h SY 5 a 102 | ! | : o Fig. 13: £03Q-M26M Fig. 12 3.3.7 REMOVE LINER, WEAR RING AND SUCTION CASING FOR “REGULABLE" PUMPS (Fig. 14, 15 and 16) ‘These pumps feature three large regulator nuts (422) which are visible on the suction side of the volute casing (400) or suction casing (416). If liner (421) needs to be replaced, with dry installed pumps, it can be removed while the volute casing or suction casing remain attached to the piping. Removal of liner: Completely remove nuts (413). To press out liner, push the three studs (412) through holes in the large regulator nuts (422) or, al three large regulator nuts can be screwed all the way into the casing. Studs (412) are locked into liner with thread-lock adhesive. Removal of studs after liner removal from casing: Studs to be heated to 150-200" to break bond, Suction casing (416) can be removed by loosening and removing nuts (417). Replace wear ring (408) if damaged. To achieve this, heat the mating surfaces with a torch to 150-200" C to destroy the special adhesive belw een these two parts. Then press out wear ring with pros. Esllsown —_-Onloneate Nome 16.07.2014 db ScieiPage 9voniet 15 NO.: 94-BA 5039ENc Q-Hydraulic.docx CaplggrovedDatiniata Namo: 2.082044 c=“fidirastal = INSTRUCTION MANUAL - Q-HYDRAULIC 3.4 _ ASSEMBLY OF HYDRAULIC PARTS + Use only cleaned and controlled parts. Testing threads for easy running. = Ensure that all O-ring mating faces are free of éamage, smooth, and of the correct form. + Check 0 - rings for damage, replace if necessary. Grease O - rings and seal faces of O - rings before assembly. - IMPORTANT: Use correct sectional drawings and corresponding parts lists for assembly. + With non-thread locked fasteners; completely lubricate the thread with assembly paste and the contact ‘surface of nut or screw-head! + Ifthread lock is recommended, to pul adhesive all around and on the whole length of thread. 3.41 INSTALL IMPELLER FLANGE ~ PUMP SIZE M ONLY (see Fig. 9 and corresponding hydraulic sectional drawing) IMPORTANTI. Preparation: For the following steps, we recommend that the drive unit is brought into vertical position with the impollor facing upwards. Coat impeller key (112) lightly with assembly paste, place the key into the keyway of the shaft and fasten with bott (142b).. ATTENTION! Coat the shatt taper lightly with assembly paste. Place impeller flange (165) onto self-locking shaft taper and ensure that key (112) engages in the groove of the impeller flange. 3.4.2 IMPELLER ASSEMBLY - MOUNTING WITH SOCKET- HEAD SCREW (Fig. 17) 4 Up to and including bolt size M42 and on older pumps of hydraulic size M with bolt size M6 the impellers are secured with socket-head screws (Fig. 4). When installing a new impelier (401) and/or new Impolter bolt (416), check length’ of the impeller bolt, Measure the impeller and impelter bolt to ensure that: 4. Length of thread engagement = at least 1.25 x thread diameter. eg. MIG: 1.25x 16 mm=20mm. 2. Thread run-out ‘G1’ of the impeller bolt is sufficient. 3. Thread run-out ‘G2'in the shaitis sufficient (shorten the impeller bolt if necessary; ensure thread engagement length under point‘). Place impeller key (112, ifinstalled) into the keyway of the shaft Fig. 17 Place impetter (401) onto the sel-locking shaft taper. ATTENTION! There are different lubrication instructions, depending on whether an impeller key (112) is used ornot: Shaft taper WITHOUT impeller key: Wet slightly with thin-badied oll. DO NOT use thick oll or grease, DO NOT use assembly paste! ‘Shafi taper WITH impeller key: Coat lighlly with assembly paste, Place impeller onto shaft. Coat front bolt thread and head contact area on the impeller generously with assembly paste. Tighten bolt to torque as shown in Table 3. Note: IF @ torque wrench is not available, the torque can be roughly determined and a tube with weight or spring balance. ved using an extension SoloiPogs 11 voniel 18 No. 94-BA 5039ENc Q-Hydraulic.docx“fidrastal —_|NSTRUCTION MANUAL - @-HYDRAULIC D The jackbolts are tightened in a small number of steps (Fig. 19/ 20}: 4. 2. See Fig. 6: On completion of impeller installation: Place protective cap (437) onto tensioner (415b) and fasten with hexagon head bolt (440). IMPORTANT! Secure bolt (440) with screw locking compound. e ATTENTION: Clearance adjustment between impeller (401) 9. Ropeat step 4 until all the jackbolts are uniformly ForMséx4: E = 1.25x56mm=70mm. Note: In the thread designation M56x4, the figure 4 stands for thread pitch P = 4 mm. In order {0 achieve the minimum insertion length, the stud bolt therefore has to be able to be ‘screwed 70 mm divided by 4 mm = 17.5 times, or rounded up, 18 turns into the shaft IMPORTANT! The minimum engaged length does not yet guarantee the correct position Of the stud bolt in the shaft; see also the following installalion steps, |. Dimension G1 Thread run-out on the impeller bolt and Dimension G2= Thread run-out in the shaft must be sufficient. Check dimensions ‘G1 and 'G2' as follows: ~ Screw in stud bolt (45a): Coat both thread ends of the cleaned stud bolt with assembly paste. - Screw the stud bolt with the hexagon head (WAF 30 mm) facing outwards into the shaft (110 or $03) tnt the dimension 70 mm es shown in Fig. 6 (projection from the tensioner contact surface in the impetier to the end of the stud bolt) is reached, and hence provisionally the correct position of the stud bolt in the shaft. - IMPORTANT: Coun! the number of bol rotations; the stud bolt must now be screwed at least 18 turns, Into the shaft The lengths 'G1" and '62' are sufficient when the stud bolt can now be screwed freely at least 2 turns further into the shaft - Screw the stud bolt back into the correct position as described above. . Replace the stud bolt (4 16a) ifit is too long or too short Place the SUPERBOLT® washer into the cleaned and lubricated recess in the impeller (Fig. 6 and 18). Ensure that the jackbotts in the clamping element are not projecting on the load side and are well lubricated. necessary, re-lubricate with the recommended lubricant, ‘Screw tensioner (415b) onto stud bolt (415a) and tighten by hand (Fig. 6) Then back off the tensioner by approx. 1/4 tun. Gap between washer and tensioner approx. 1 mm (Fig. 18) ‘Number four jackbolts from 1-4 (option: matk with a marker ppen) and fighten crosswise by hand or using a small wrench to centro the main thread and compensate any play. Nov tighten thse 4 jackbolts crosswise to 50% of the specified tightening torque M. TTighton the samo 4 jackbolts crosswise to 100% of the specified tightening torque M. Now change to circular tightening and tighten all jackbolts to 100% of the specified tightening torque M. tightened (less than 20° remaining movemen!). 2 to 3 repetitions are normally sufficient, wih longer bolts correspondingly more. ‘and back cover (507) / back-cone (511) see section 3.2.5. tlskown Datunite Name: 16.07.2014 a SoieiPage 18 vonie! 16 No.1 94-BA 5039ENc Q-Hydraulic.docx Goprofteprevod-Datunlta Nome: 23 00.2014 es~Pidrastal —_ WsTRUCTION MANUAL - Q-HYDRAULIC 3.5 FINAL ASSEMBLY |f (411) Is @ spacer ring instead of shims, place it over spigot of drive unit, Insert O-ring (209) into groove of bback-caver (507) or back-cone (511) of drive unit. Now install drive unit-impeller assembly into volute casing (400) using a suitable hoist. ATTENTION: Impeller ~ clearance adjustment in accordance with section 3.2, When new hydraulic parts have been installed (volute casing, impeller, liner, suction casing or wear ring), or impelter clearance is reduced through changing of adjusting-shims (411), the following clearance check must be carried out: With correcty adjusted impoler- clearanca ‘’ (Table 2), clearance betweon impeller-tip and wear ring (408), linet (421) or suction cover (402) has to be at least the minimum of 1 mm (ig. 3). in case, that this clearance is too small, grind off the impeler tip, parallel to suction flange, until approx. 1 to 2 mm clearance is achieved. Tightening fasteners (419). Etteudraun _-Dalundata Namo: 167.2044 a> SoieiPage 15 voniol'5 No. 94-BA 6039ENc Q-Hydraullic.docx Gringo -Datunlte Name: 23.08.2014 23