Goulds Pumps 3409 User Manual

Installation, Operation and Maintenance Instructions

Model 3409

Pump Safety Tips

Safety Apparel:

l

Insulated work gloves when handling hot bearings or
using bearing heater

l

Heavy work gloves when handling parts with sharp
edges, especially impellers

l

Safety glasses (with side shields) for eye protection,
especially in machine shop areas

l

Steel-toed shoes for foot protection when handling parts,
heavy tools, etc.

l

Other personal protective equipment to protect against
hazardous/toxic fluids

Coupling Guards:

l

Never operate a pump without a coupling guard properly
installed

Flanged Connections:

l

Never force piping to make a connection with a pump

l

Use only fasteners of the proper size and material

l

Ensure there are no missing fasteners

l

Beware of corroded or loose fasteners

Operation:

l

Do not operate below minimum rated flow, or with
suction/discharge valves closed

l

Do not open vent or drain valves, or remove plugs while
system is pressurized

Maintenance Safety:

l

Always lock out power

l

Ensure pump is isolated from system and pressure is
relieved before disassembling pump, removing plugs, or
disconnecting piping

l

Use proper lifting and supporting equipment to prevent
serious injury

l

Observe proper decontamination procedures

l

Know and follow company safety regulations

Observe all cautions and warnings highlighted in pump

Installation, Operation and Maintenance Instructions.

IMPORTANT SAFETY REMINDER

To: Our Valued Customers

Goulds' pumps will provide safe, trouble-free service when properly installed, maintained, and operated. We have an
extensive network of experienced sales and service professionals to assist in maximizing your satisfaction with our products.

Safe installation, operation, and maintenance of Goulds' equipment are an essential end user responsibility. This Instruction,
Operation, and Maintenance (IOM) manual identifies specific safety risks that must be considered at all times during product
life. Understanding and adhering to these safety warnings is mandatory to ensure personnel, property, and/or the environment
will not be harmed. Adherence to these warnings alone, however, is not sufficient — it is anticipated that the end user will also
comply with industry and corporate safety standards. Identifying and eliminating unsafe installation, operating and maintenance
practices is the responsibility of all individuals involved in the installation, operation, and maintenance of industrial equipment.

Specific to pumping equipment, two significant risks bear reinforcement above and beyond normal safety precautions.

! WARNING

▲

Operation of any pumping system with a blocked suction and discharge must be avoided in all cases. Operation, even

for a brief period under these conditions, can cause superheating of enclosed pumpage and result in a violent explosion.

1

All necessary measures must be taken by the end user to ensure this condition is avoided.

! WARNING

▲

Pumping equipment Instruction, Operation, and Maintenance manuals clearly identify accepted methods for
disassembling pumping units. These methods must be adhered to. Specifically, applying heat to impellers and/or

2

impeller retaining devices to aid in their removal is strictly forbidden. Trapped liquid can rapidly expand and result
in a violent explosion and injury.

Please take the time to review and understand the safe installation, operation, and maintenance guidelines outlined in this
manual.

3409 IOM 11/04 3

4 3409 IOM 11/04

FOREWORD

This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Pumps
Model 3409 Double Suction, Horizontally Split Case Pump. This manual covers the standard product
plus common options that are available. For special options, supplemental instructions are supplied.

This manual must be read and understood before installation and maintenance.

The design, materials, and workmanship incorporated in the construction of Goulds pumps make them
capable of giving long, trouble-free service. The life and satisfactory service of any mechanical unit,
however, is enhanced and extended by correct application, proper installation, periodic inspection,
condition monitoring and careful maintenance. This instruction manual was prepared to assist operators
in understanding the construction and the correct methods of installing, operating, and maintaining these
pumps.

ITT Industries - Goulds Pumps shall not be liable for physical injury, damage or delays caused by
a failure to observe the instructions for Installation, Operation, and Maintenance contained in this
manual.

NOTE: When pumping unit is installed in a potentially explosive atmosphere, the instructions after the Ex symbol

!

must be followed. Personal injury and/or equipment damage may occur if these instructions are not followed. If
there is any question regarding these requirements or if the equipment is to be modified, please contact a Goulds
representative before proceeding.

Warranty is valid only when genuine ITT Industries - Goulds Pumps parts are used.

Use of the equipment on a service other than stated in the order will nullify the warranty, unless written
approval is obtained in advance from ITT Industries - Goulds Pumps.

Supervision by an authorized ITT Industries - Goulds Pumps representative is recommended to assure
proper installation.

Additional manuals can be obtained by contacting your local ITT Industries - Goulds Pumps
representative or by calling 1-(800)-446-8537.

THIS MANUAL EXPLAINS

Proper Installation

n

Start-up Procedures

n

Operation Procedures

n

Routine Maintenance

n

Pump Overhaul

n

Troubleshooting

n

Ordering Spare or Repair Parts

n

3409 IOM 11/04 5

6 3409 IOM 11/04

TABLE OF CONTENTS

PAGE

9 SAFETY

13 GENERAL INFORMATION

15 INSTALLATION

27 OPERATION

31 PREVENTIVE MAINTENANCE

SECTION

1

1

2

3

4

5

39 DISASSEMBLY & REASSEMBLY

55 APPENDICES

55 I - Instructions for Ordering Parts

57 II - Tools

59 III - Engineering Data

61 IV - Cross Sectional

63 V - Replacement Parts List

65 VI - Useful Formulas

67 VII - Field Test Report Form

6

7

3409 IOM 11/04 7

8 3409 IOM 11/04

SAFETY

DEFINITIONS......................................9

GENERAL PRECAUTIONS .............................10

EXPLOSION PREVENTION .............................10

SPECIAL ATEX CONSIDERATIONS........................10

ATEX IDENTIFICATION ..............................11

INTENDED USE ....................................11

CONDITION MONITORING ............................11

DEFINITIONS

2

This pump has been designed for safe and reliable
operation when properly used and maintained in
accordance with instructions contained in this manual. A
pump is a pressure containing device with rotating parts
that can be hazardous. Operators and maintenance
personnel must realize this and follow safety measures.
ITT Industries - Goulds Pumps shall not be liable for
physical injury, damage or delays caused by a failure to
observe the instructions in this manual.

Throughout this manual the words WARNING,
CAUTION, ELECTRICAL, ATEX and NOTE are used
to indicate procedures or situations which require special
operator attention:

! WARNING

s

WARNING is used to indicate the presence of a hazard
which can cause severe personal injury, death, or
substantial property damage if the warning is ignored.

CAUTION

$

CAUTION is used to indicate the presence of a hazard
which will or can cause minor personal injury or
property damage if the warning
is ignored.

!

EXAMPLES

! WARNING

s

Pump shall never be operated without coupling guard
installed correctly.

CAUTION

$

Throttling flow from the suction side may
cause cavitation and pump damage.

Improper impeller adjustment could cause contact

!

between the rotating and stationary parts, resulting
in a spark and heat generation.

Lock out driver power to prevent electric shock,

!

accidental start-up and physical injury.

NOTE: Proper alignment is essential for long pump
life.

!

If equipment is to be installed in a potentially

!

explosive atmosphere and these procedures are not
followed, personal injury or equipment damage from
an explosion may result.

Particular care must be taken when the electrical

"

power source to the equipment is energized.

NOTE: Operating procedure, condition, etc. which is
essential to observe.

3409 IOM 11/04 9

GENERAL PRECAUTIONS

! WARNING

s

Personal injuries will result if procedures outlined in
this manual are not followed.

NEVER operate pump without coupling

!#

A

AD
AD
AD

guard correctly installed.

NEVER operate pump beyond the rated
conditions to which the pump was sold.

NEVER start pump without proper prime
(sufficient liquid in pump casing).

NEVER run pump below recommended
minimum flow or when dry.

ALWAYS lock out power to the driver

!

C

A
AD

A

!

"

before performing pump maintenance.
NEVER operate pump without safety

#

devices installed.
NEVER operate pump with discharge

#

valve closed.
NEVER operate pump with suction valve

closed.
DO NOT change conditions of service

without approval of an authorized Goulds
representative.

! WARNING

s

If pump is to be used on process fluids above 120°
F, pump surface temperatures could be warm
enough to cause burns. We recommend pump
surfaces be insulated. Failure to follow these
instructions could result in severe personal injury.

EXPLOSION PREVENTION

In order to reduce the possibility of accidental explosions in atmospheres containing explosive gases and/or dust, the

!

instructions under the ATEX symbol must be closely followed. ATEX certification is a specification enforced in
Europe for non- electrical and electrical equipment installed in Europe. The usefulness of the ATEX requirements is
not limited to Europe. They are useful guidelines for equipment installed in any potentially explosive environment.

SPECIAL ATEX CONSIDERATIONS

All installation and operation instructions in this manual
must be strictly adhered to. In addition, care must be taken
to ensure that the equipment is properly maintained. This
includes but is not limited to:

1. Monitoring the pump frame and liquid end
temperature.

2. Maintaining proper bearing lubrication.

3. Ensuring that the pump is operated in the intended
hydraulic range.

10 3409 IOM 11/04

ATEX IDENTIFICATION

For a pumping unit (pump, seal, coupling, motor and pump
accessories) to be certified for use in an ATEX classified
environment, the proper ATEX identification must be
present.

The ATEX tag would be secured to the pump or the
baseplate on which it is mounted. A typical tag would look
like this:

The CE and the Ex designate the ATEX compliance. The
code directly below these symbols reads as follows:

II =
2=
G/D =
T4 =

Group 2

Category 2

Gas and Dust present

Temperature class, can be T1 to T6

(see Table 1)

Table 1

Max

Max permissible

surface

temperature

Code

T1 842 (450) 700 (372)
T2 572 (300) 530 (277)
T3 392 (200) 350 (177)
T4 275 (135) 235 (113)
T5 212 (100) Option not

T6 185 (85) Option not

The code classification marked on the equipment should be
in accordance with the specified area where the equipment
will be installed. If it is not, please contact your
ITT/Goulds representative before proceeding.

o

F(oC)

permissible

liquid

temperature

o

F(oC)

available

available

INTENDED USE

The ATEX conformance is only applicable when the pump
unit is operated within its intended use. All instructions
within this manual must be followed at all times.
Operating, installing or maintaining the pump unit in any
way that is not covered in this manual can cause serious
personal injury or damage to the

CONDITION MONITORING

For additional safety precautions, and where noted

!

in this manual, condition monitoring devices should
be used. This includes, but is not limited to:

u

Pressure gauges

u

Flow meters

u

Level indicators

u

Motor load readings

u

Temperature detectors

u

Bearing monitors

u

Leak detectors

u

PumpSmart control system

equipment. This includes any modification to the
equipment or use of parts not provided by ITT/Goulds. If
there is any question regarding the intended use of the
equipment, please contact an ITT/Goulds representative
before proceeding.

For assistance in selecting the proper instrumentation and
its use, please contact your ITT/Goulds representative.

3409 IOM 11/04 11

12 3409 IOM 11/04

GENERAL INFORMATION

PUMP DESCRIPTION ................................13

NAMEPLATE INFORMATION ...........................14

PUMP DESCRIPTION

This product line consists of 12 sizes of double suction,
horizontally split case pumps from size 6x10-22 through
size 14x18-28.

Casing - The casing shall be close-grained Cast Iron or
Ductile Iron, and shall be of axially-split double-volute
design with suction and discharge flanges and mounting
feet cast integral with the lower half casing. Tapped and
plugged holes shall be provided for priming, vent, drain
and gauge connections. Upper half casing shall be
removable without disturbing suction or discharge piping.
Flanges shall be of (125/125#) (125/250#) (250/250#) ASA
Standard. Suction and Discharge shall be on a common
centerline in both the horizontal and vertical planes.

Impeller - The impeller shall be of the enclosed
double-suction type made of (bronze) (ductile iron) (316
stainless steel) and statically and hydraulically balanced.
The impeller shall be keyed to the shaft and positioned
axially by the shaft sleeves. Hub shall have sufficient metal
thickness to allow machining for installation of impeller
rings.

Shaft - The shaft shall be made of (AISI 4140, 316
stainless steel, 17-4 ph) and be of ample size to operate
under load with of minimum deflection.

Shaft Sleeves - The shaft sleeves shall be made of (bronze)
(420 hardened stainless steel) [packing only] (316 stainless
steel)(cast iron) and shall protect the shaft from wear and
from contact with the pumped liquid. An O-ring shall be
furnished under sleeve to prevent leakage.

Stuffing Box - The stuffing box shall consist of at least six
(6) rings of die formed, graphite acrylic yarn packing and a
split type gland to permit removal and access to packing.
Ample space shall be provided for repacking the stuffing
box. Arrangement shall provide for field or factory
conversion to mechanical seals without machine work.

Casing Rings - The casing rings shall be made of (bronze)
(cast iron) (Nitronic 60 stainless steel) and shall be
installed with an anti-rotation device.

Bearings - The bearings shall be grease lubricated or oil
lubricated. The inboard or coupling end bearing shall be a
single row ball bearing. The outboard bearing shall be a
double row cylindrical roller bearing which is retained by
bearing locknut and lockwasher.

Bearing Housings - The bearing housings shall be bolted
to the end of the lower half casing and shall assure positive
alignment of the rotating element. The housings shall
provide a fit for the inboard bearing that allows freedom
for thermal expansion while the outboard bearing shall be
clamped in place to take all thrust loads and keep the
rotating element in its proper axial location.

Baseplate - The baseplate shall be sufficiently rigid to
support the pump and driver and shall be steel with a drip
pan beneath the pump end. The drip pan shall contain a
tapped drain connection.

Coupling - Coupling shall be an all metal type.

The coupling used in an ATEX classified

!

environment must be properly certified.

Coupling Guard - The coupling guard shall be all metal.

The coupling guard used in an ATEX classified

!

environment must be constructed from a non­sparking material.

Rotation - Pump shall have clockwise or counterclockwise

rotation when viewed from its
driven end.

3409 IOM 11/04 13

NAMEPLATE INFORMATION

Every pump has a Goulds Pumps nameplate that provides
information about the pump. The nameplate is located on
the pump casing.

Special tags which provide additional information
(mechanical seal data, etc.) and special tagging required by
customers are located on the pump casing or on the bearing
frame.

The standard nameplate (Fig. 1) provides information about
the pump size, type, serial number, rated head, capacity,
speed, impeller diameter, model number, and maximum
field hydrostatic test pressure.

The identification No. is a number which the end user of
the pump requests to be put on the nameplate to identify the
pump in his operation.

The year indicates the year in which the pump was built.

Rating and hydrostatic test pressure are expressed in
English units. Note the format of pump size: Discharge x
Suction - Nominal Impeller Diameter in inches, for
example, 6x10-22.

The frame plate provides information concerning the
bearings and their lubrication. The inboard and outboard
bearing numbers refer to the bearing manufacturer’s
numbers.

When ordering spare parts you will need to identify pump
model, size, serial number, and the catalog number of
required parts. Pump information can be taken from the
Goulds Pumps nameplate. Catalog numbers can be found in
this manual.

Fig. 1

If applicable, your pump unit may have the following
ATEX tag affixed to the pump and/or baseplate. See the
Safety section for a description of the symbols and codes.

14 3409 IOM 11/04

INSTALLATION

RECEIVING THE PUMP ...............................15

LIFTING THE PUMP .................................15

Horizontal ......................................15

Vertical .......................................16

STORAGE .......................................17

Temporary ......................................17

Long Term ......................................17

LOCATION.......................................18

FOUNDATION .....................................18

SETTING THE BASEPLATE ............................18

Grouting Procedure .................................19

ALIGNMENT PROCEDURE.............................19

Method One .....................................20

Method Two .....................................20

DOWELING ......................................21

SUCTION AND DISCHARGE PIPING .......................21

Suction Piping ....................................22

Discharge Piping...................................23

Pressure Gauges ...................................23

STUFFING BOX LUBRICATION ..........................24

Packing .......................................24

Mechanical Seals ..................................24

Cartridge Seals....................................25

Cyclone Separators .................................25

3

RECEIVING THE PUMP

Check pump for shortages and damage immediately upon
arrival (an absolute must!). Prompt reporting to the
carrier’s agent, with notations made on the freight bill, will
expedite satisfactory adjustment by the carrier.

Pumps and drivers are normally shipped from the factory
mounted on a baseplate. Couplings may either be
completely assembled or have the coupling hubs mounted

LIFTING THE PUMP

The following instructions are for the safe lifting of your
pump.

The unit should be unloaded and handled by lifting equally
at four or more points on the baseplate. The lugs on the
upper half casing are designed for lifting the upper half
casing only.

on the shafts and the connecting members removed. When
the connecting members are removed, they will be
packaged in a separate container and shipped with the
pump or attached to the baseplate.

HORIZONTAL

Bare Pump

1. Using a nylon sling, chain, or wire rope, hitch around

both bearing housings. (See Fig. 2)

3409 IOM 11/04 15

DO NOT LIFT
ENTIRE PUMP
WITH THESE
LUGS.

Fig. 2

Pump, Base, and Driver

2. Care must be taken to size equipment for unbalanced
loads which may exist if the driver is not mounted on
the base at the time of lifting. Driver may or may not
be mounted at the factory.

Using ANSI/OSHA Standard “S” hooks, place the “S” hooks in
the holes provided in the four corners of the base. Be sure the
points of the hooks do not touch the bottom of the pump base.
Attach nylon slings, chains, or wire rope to the “S” hooks. Size the
equipment for the load so the lift angle will be less than 45° from
the vertical.

Bases supplied without lifting holes

Place one sling around the outboard bearing housing.

! WARNING

s

Do not use lugs on top half of casing.

Place the remaining sling around the back end of the driver as
close to the mounting feet as possible. Make certain sling will not
damage housing cover or conduit boxes.

Join the free ends of the slings together and place over the lifting
hook. Use extreme care when positioning sling under the driver
so it cannot slip off. (See Fig. 4)

3. Pump, base, and driver assemblies where the base
length exceeds 100 inches may not be safe to lift as a
complete assembly. Damage to the baseplate may
occur. If the driver has been mounted on the baseplate
at the factory, it is safe to lift the entire assembly. If
driver has not been mounted at the factory and the
overall baseplate length exceeds 100 inches, do not lift
entire assembly consisting of pump, base, and driver.
Instead, lift the pump and baseplate to its final location
without the driver. Then mount the driver.

Bases supplied with lifting holes

Large bases are supplied with lifting holes in the sides or
the ends of the base. (See Fig. 3)

Fig. 4

VERTICAL

Half Pedestal

1. Place nylon sling chain or wire rope around both
flanges. Use a latch hook or standard shackle and end
loops.

Be sure the lifting equipment is of sufficient length to
keep the lift angle less than 30° from the vertical. (See
Fig. 5)

Full Pedestal

2. Install eyebolts in the three holes provided at the top of the
support, being sure to tighten securely. Attach chain or wire
rope using latch hook or standard shackle and end loop.

Be sure to use shoulder eyebolts that are manufactured per
ANSI B18.15 and sized to fit the holes provided.

Be sure lifting equipment is of sufficient length to keep
the lift angle less than 30° from the vertical.
(See Fig. 6)

Fig. 3

16 3409 IOM 11/04

Fig. 5

STORAGE

Fig. 6

3

The following storage procedures apply to the pump only.
Other accessories such as motors, steam turbines, gears,
etc., must be handled per the respective manufacturer’s
recommendations.

TEMPORARY

Temporary storage is considered one month or less.
If the pump is not to be installed and operated soon after
arrival, store it in a clean, dry place having slow, moderate
changes in ambient temperature. Rotate the shaft
periodically to coat the bearings with lubricant and to retard
oxidation, corrosion, and to reduce the possibility of false
brinelling of the bearings. Shaft extensions and other
exposed machine surfaces should be coated with an easily
removable rust preventative such as Ashland Oil Tectyl No.
502C.

For oil lubricated bearings, fill the frame completely with
oil. Before putting equipment into operation, drain the oil
and refill to proper level.

LONG TERM

Storage longer than one month is considered long term
storage. Follow the same procedure for temporary storage
with the following addition. Add one half ounce of a
corrosion inhibiting concentrated oil such as Cortec Corp.
VCI-329 (for both grease and oil lubricated bearings). Seal
all vents and apply a water proof tape around the oil seals
in the bearing frame. Remember for oil lubricated bearings
to drain the oil from the frame and refill to the proper level
before running pump.

3409 IOM 11/04 17

LOCATION

The pump should be installed as near the suction supply as
possible, with the shortest and most direct suction pipe
practical. The total dynamic suction lift (static lift plus
friction losses in suction line) should not exceed the limits
for which the pump was sold.

The pump must be primed before starting. Whenever
possible, the pump should be located below the fluid level
to facilitate priming and assure a steady flow of liquid. This
condition provides a positive suction head on the pump. It
is also possible to prime the pump by pressurizing the
suction vessel.

Pumps must be fully primed at all times during

!

operation.

When installing the pump, consider its location in relation
to the system to assure that sufficient Net Positive Suction
Head (NPSHA) is available at the pump inlet connection.
Available NPSH must always equal or exceed the required
NPSH (NPSHR) of the pump.

FOUNDATION

The foundation must be substantial enough to absorb
vibration. (Hydraulic Institute Standards recommends the
foundation weigh at least five [5] times the weight of the
pump unit.) It must form a permanent and rigid support for the
baseplate. This is important in maintaining the alignment of a
flexibly coupled unit.

The pump should be installed with sufficient accessibility for
inspection and maintenance. A clear space with ample head
room should be allowed for the use of an overhead crane or
hoist sufficiently strong to lift the unit.

NOTE: Allow sufficient space to be able to dismantle
pump without disturbing the pump inlet and discharge
piping.

Select a dry place above the floor level wherever possible. Take
care to prevent pump from freezing during cold weather when
not in operation. Should the possibility of freezing exist during a
shut-down period, the pump should be completely drained, and
all passages and pockets where liquid might collect should be
blown out with compressed air.

Make sure there is a suitable power source available for the
pump driver. If motor driven, the electrical characteristics of the
power source should be identical to those shown on motor data
plate.

The foundation should be poured to within .75" - 1.5" of
the finished height. (See Fig. 7) Freshly poured foundations
should be allowed to cure for several days before the unit is
set in place and grouted.

Foundation bolts of the proper size should be embedded in the
concrete to a depth of eight (8) to twelve (12) inches and
locked with either a hook around a reinforcing bar or
alternatively, a nut and washer at the bottom. The bolts should
have a sleeve around them at least six (6) times the bolt
diameter in length and at least two (2) bolt sizes larger in I.D.
If a nut and washer are used for locking, the washer should
have an O.D. two (2) sizes larger than the sleeve. Foundation
bolts should be sized .125" less than the anchor bolt holes in
the base.

SETTING THE BASEPLATE

Pump units are checked at the factory for align ability to
required tolerances.

Due to flexibility of an ungrouted base and handling in
shipment, it should not be assumed that the unit is in
alignment when it is placed on the rough foundation.

If these directions are followed, the required alignment should
be readily achieved.

Fig. 7

Initial or rough alignment must be done prior to grouting of
baseplate. Rough alignment is designated as .020" TIR (Total
Indicator Reading) parallel alignment and .009" TIR per inch of
radius angular alignment (See ALIGNMENT PROCEDURE).
Use blocks at anchor bolts and midway between to position
bottom of base at finished height (See Fig. 8) with foundation
bolts extending through holes in the baseplate. Metal wedges
with a small taper may be used in lieu of blocks and shims.

18 3409 IOM 11/04

Fig. 8

If the unit has a non-flexible coupling (e.g. Falk Gear coupling),
the coupling halves should be disconnected; this is generally not
necessary on flexible type couplings (e.g. Wood’s Sure-Flex
coupling).

NOTE: The baseplate does not have to be level.

After foundation bolts are lightly torqued, recheck
alignment requirements once more. Follow requirements
outlined at the beginning of this section. If alignment must
be corrected, add or remove shims or wedges under the
baseplate.

The unit can then be grouted. (See Fig. 8)

Grout compensates for the uneven foundation. Together
with the baseplate, it makes a very rigid interface between
the pump and the foundation distributing the weight over
the length of the base and preventing shifting.

Use an approved, non-shrinking grout such as Embeco 636
or 885 by Master Builders, Cleveland, Ohio or equivalent.

3

GROUTING PROCEDURE

1. Build a strong form around the foundation to contain
the grout.

Tighten up all pump and motor bolts to assure they have not
loosened or a “soft foot” has occurred due to base distortion in
shipment. A “soft foot” causes a change in the alignment when
unloosening one bolt.

If the driver is being field installed, it should be centered in its
bolt holes with shims added to bring the driver into rough
alignment with the pump. (The pump may have to be moved
also.)

$

Do not exceed six (6) shims, using as thick a shim as
possible, otherwise “sponginess” or “soft foot” will result.
Place thin shims in between thick shims.

Level and plumb the pump shaft, coupling faces and flanges by
adding or removing shims between the blocks and the bottom
of the base. Hand tighten the anchor bolt nuts at first. Being
very careful not to distort the base, snug down the nuts with a
wrench. The non-flexible coupling should not be reconnected
until the alignment operation has been completed.

!CAUTION

ALIGNMENT PROCEDURE

2. Soak the top of the foundation thoroughly, then
remove surface water.

3. The baseplate should be completely filled with grout
and, if necessary, temporarily use air relief tubing or
drill vent holes to remove trapped air.

4. After the grout has thoroughly hardened
(approximately 24 hours), tighten the foundation bolts
fully.

5. Check the alignment after the foundation bolts are
tightened.

6. Approximately fourteen (14) days after the grout has
been poured and the grout has thoroughly dried, apply
an oil base paint to the exposed edges of the grout to
prevent air and moisture from coming in contact with
the grout.

Alignment procedures must be followed to prevent

!

unintended contact of rotating parts. Follow
coupling manufacturer's installation and operation
procedures.

Proper rough alignment must be made during unit setting
and grouting. See previous section.

There are two forms of misalignment between the pump
shaft and the driver shaft as follows:

1. Angular misalignment — shafts have axis concentric
at intersection, but not parallel.

3409 IOM 11/04 19

2. Parallel offset misalignment — shafts have axis
parallel, but offset.

The necessary tools for checking alignment are: (1) a straight
edge and a taper gauge or set of feeler gauges or, (2) a dial
indicator with mounting magnet and extension bars.

Check and correct for angular misalignment before correcting
parallel alignment. Final alignment should be made by moving
and shimming the motor on its base until the coupling hubs are
within the recommended tolerances measured in total run out.
All measurements should be taken with the pump and driver

bolts tightened. Final alignment check should be made after
the unit has attained its final operating temperature.

Method 1 - Using straight edge and taper gauges or feelers
(Fig. 9):

Proceed with this method only if satisfied that face and
outside diameters of the coupling halves are square and
concentric with the coupling bores. If this condition does
not exist or elastomeric couplings do not make this method
convenient, use Method 2.

Check for angular alignment by inserting the taper or feeler

gauges between the coupling faces at 90° intervals. The
unit is in angular alignment when these four (4)
measurements are the same, or within recommended
tolerances.

Check for parallel alignment by placing a straight edge
across both coupling rims on all four sides. The unit is in
parallel alignment when the straight edge rests evenly
across both coupling rims in all four (4) positions.

Method 2 - Dial Indicators (Fig. 10):

A dial indicator can be used to attain more accurate
alignment.

Fasten the indicator stand or magnetic base to the pump
half of the coupling and adjust the assembly until the
indicator button is resting on the other half coupling
periphery.

Set the dial to zero and chalk mark the coupling half where
the button rests. Also place a separator between the
coupling halves so bearing slack does not affect the
readings. (Chalk and separators are not necessary on the
elastomeric couplings that have not been disconnected.)
Rotate both shafts by the same amount; i.e., all readings
must be made with the button on the chalk mark.

The dial readings will indicate whether the driver has to be
raised, lowered or moved to either side. Accurate alignment
of shaft centers can be obtained with this method even
where faces or outside diameters of the coupling are not
square or concentric with the bores. After each adjustment,
recheck both parallel and angular alignments.

Fig. 9

NOTE: Gross deviations in squareness or
concentricity may cause rotation unbalance problems
and if so must be corrected.

PERMISSIBLE COUPLING MISALIGNMENT

Parallel

Angular

Single Element

Coupling

.004” TIR

(4 mils)

.004” TIR per inch

of radius.

Double Element

(spacer) Coupling

.060” TIR

per foot of spacer

length

.002” TIR

per inch of radius

20 3409 IOM 11/04

DOWELING

Fig. 10

3

Pump units may, if desired, (or required in specification) be
doweled on diagonally opposite feet. This should not be

SUCTION AND DISCHARGE PIPING

Flange loads from the piping system, including those

!

from thermal expansion of the piping, must not
exceed the limits of the pump. Casing deformation
can result in contact with rotating parts which can
result in excess heat generation, sparks and
premature failure.

The introduction of pumpage into a piping system which is not
well designed or adjusted may cause strain on the pump, leading
to misalignment or even impeller rubbing. Since slight strain may
go unnoticed, final alignment should be done with the system full
and up to final temperature.

Pipe flanges should not impose any strain on the pump. This can
be checked by a dial indicator. Any strain must be corrected by
adjustments in the piping system.

When installing the pump piping, be sure to observe the following
precautions:

done until the unit has been run for a sufficient length of
time and alignment is within the above alignment tolerance.

to prevent pipe strain. Do not install expansion joints next to the
pump or in any way that would cause a strain on the pump
resulting from system pressure changes. When using rubber
expansion joints, follow the recommendations of the Technical

Handbook on Rubber Expansion Joints and Flexible Pipe
Connectors. It is usually advisable to increase the size of both

suction and discharge pipes at the pump connections to decrease
the loss of head from friction.

Install piping as straight as possible, avoiding unnecessary bends.
Where necessary, use 45° or long radius 90° fittings to decrease
friction losses.

Make sure that all piping joints are air-tight.

Where flanged joints are used, assure that inside diameters match
properly.

Remove burrs and sharp edges when making up joints.

Piping should always be run to the pump.

Do not move the pump to pipe. This could make final alignment
impossible.

Both the suction and discharge piping should be independently
anchored near the pump and properly aligned so that no strain is
transmitted to the pump when the flange bolts are tightened. Use
pipe hangers or other supports at necessary intervals to provide
support. When expansion joints are used in the piping system they
must be installed beyond the piping supports closest to the pump.
Tie bolts and spacer sleeves should be used with expansion joints

3409 IOM 11/04 21

Fig. 11

Do not “spring” piping when making any connections.

Provide for pipe expansion when hot fluids are to be pumped.

SUCTION PIPING

When installing the suction piping, observe the following
precautions. (See Fig. 12)

The sizing and installation of the suction piping is extremely
important. It must be selected and installed so that pressure
losses are minimized and sufficient liquid will flow into the
pump when started and operated.

Many NPSH (Net Positive Suction Head) problems can be
directly attributed to improper suction piping systems.

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

1. If the pump is operating under static suction lift
conditions, a foot valve may be installed in the suction
line to avoid the necessity of priming each time the
pump is started. This valve should be of the flapper
type, rather than the multiple spring type, sized to
avoid excessive friction in the suction line. (Under all
other conditions, a check valve, if used, should be
installed in the discharge line. See Discharge Piping.)

2. When foot valves are used, or where there are other
possibilities of “water hammer,” close the discharge
valve slowly before shutting down the pump.

Suction piping should be short in length, as direct as
possible, and never smaller in diameter than the pump
suction opening. A minimum of five (5) pipe diameters
between any elbow or tee and the pump should be allowed.
If a long suction pipe is required, it should be one or two
sizes larger than the suction opening, depending on its
length.

$

An elbow should not be used directly before the suction of
a double suction pump if its plane is parallel to the pump
shaft. This can cause an excessive axial load or NPSH
problems in the pump due to an uneven flow distribution
(See Fig. 11). If there is no other choice, the elbow should
have straightening vanes to help evenly distribute the flow.

Eccentric reducers should be limited to one pipe size
reduction each to avoid excessive turbulence and noise.
They should be of the conical type. Contour reducers are
not recommended.

When operating on a suction lift, the suction pipe should
slope upward to the pump nozzle. A horizontal suction line
must have a gradual rise to the pump. Any high point in the
pipe can become filled with air and prevent proper
operation of the pump. When reducing the piping to the
suction opening diameter, use an eccentric reducer with the
eccentric side down to avoid air pockets.

CAUTION

3. Where two or more pumps are connected to the same
suction line, install gate valves so that any pump can
be isolated from the line. Gate valves should be
installed on the suction side of all pumps with a
positive pressure for maintenance purposes. Install
gate valves with stems horizontal to avoid air pockets.
Globe valves should not be used, particularly where
NPSH is critical.

$

The pump must never be throttled by the use of a valve
on the suction side of the pump. Suction valves
should be used only to isolate the pump for mainten­ance purposes, and should always be installed in
positions to avoid air pockets.

CAUTION

3

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

Fig. 12 shows some correct and incorrect suction piping
arrangements.

22 3409 IOM 11/04

DISCHARGE PIPING

If the discharge piping is short, the pipe diameter can be the
same as the discharge opening. If the piping is long, the
pipe diameter should be one or two sizes larger than the
discharge opening. On long horizontal runs, it is desirable
to maintain as even a grade as possible. Avoid high spots,
such as loops, which will collect air and throttle the system
or lead to erratic pumping.

A check valve and an isolating gate valve should be
installed in the discharge line. The check valve, placed
between pump and gate valve, protects the pump from
excessive back pressure, and prevents liquid from running
back through the pump in case of power failure. The gate
valve is used in priming and starting, and when shutting the
pump down.

PRESSURE GAUGES

Properly sized pressure gauges should be installed in both
the suction and discharge nozzles in the gauge taps
provided. The gauges will enable the operator to easily
observe the operation of the pump, and also determine if
the pump is operating in conformance with the
performance curve. If cavitation, vapor binding, or other
unstable operation should occur, widely fluctuating
discharge pressure will be noted.

3

Fig. 12

3409 IOM 11/04 23

STUFFING BOX LUBRICATION

Contaminants in the pumped liquid must not enter the
stuffing box. These contaminants may cause severe
abrasion or corrosion of the shaft, or shaft sleeve, and rapid
packing or mechanical seal deterioration; they can even
plug the stuffing box flushing and lubrication system. The
stuffing box must be supplied at all times with a source of
clean, clear liquid to flush and lubricate the packing or seal.
The most important consideration is to establish the
optimum flushing pressure that will keep contaminants
from the stuffing box cavity. If this pressure is too low,
fluid being pumped may enter the stuffing box. If the
pressure is too high, excessive packing or seal wear may
result; and extreme heat may develop in the shaft causing
higher bearing temperatures. The most desirable condition,
therefore, is to use a seal water pressure 15-20 psig above
the maximum stuffing box pressure.

If the pump system pressure conditions vary, packing
adjustment becomes difficult. Consideration should be
given to using a mechanical seal. (See Mechanical Seals.)

PACKING

Packed stuffing boxes are not allowed in an ATEX

!

classified environment.

Standard pumps are normally shipped with the packing set
loose (not installed). If the pump is installed within 60
days after shipment, the packing will be in good condition
with a sufficient supply of lubrication. If the pump is stored
for a longer period, it may be necessary to replace the
factory supplied packing set. In all cases, however, inspect
the packing before it is installed and the pump started.

general, external-injection liquid (from an outside source)
is required when any of the above conditions cannot be
met.

The standard stuffing box consists of six (6) rings of
packing and a split type gland. A shaft sleeve which
extends through the box and under the gland is provided to
protect the shaft.

A tapped hole is supplied in the stuffing box directly over
the seal cage to introduce a clean, clear sealing medium.
The stuffing box must, at all times, be supplied with sealing
liquid at a high enough pressure to keep the box free from
foreign matter, which would quickly destroy the packing
and score the shaft sleeve.

Only a sufficient volume of sealing liquid to create a
definite direction of flow from the stuffing box inward to
the pump casing is required, but the pressure is important.
Apply seal water at a rate of approximately .25 GPM at a
pressure approximately 15 to 20 psig above the suction
pressure. (Approximately one [1] drop per second.)

One recommended method to minimize error in regulating
flushing water is a “Controlled Pressure System.” (Fig. 13)
Most important is the pressure reducing valve adjusted to a
value slightly exceeding the maximum stuffing box
operating pressure (assuming it is reasonably constant). A
flow indicating device will serve to indicate a failing of the
bottom packing rings allowing leakage in the pump.

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

On some applications, it is possible to use internal liquid
lubrication (pumped liquid) to lubricate packing. Only
when all of the conditions prevail, can this be done:

1. Liquid is clean, free from sediment and chemical
precipitation and is compatible with seal materials.

2. Temperature is above 32° F and below 160° F.

3. Suction pressure is below 75 psig.

4. Lubrication (pumped liquid) has lubricating qualities.

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

When the liquid being pumped contains solids or is
otherwise not compatible with packing materials, an
outside supply of seal liquid should be furnished. In

External sealing liquid should be adjusted to the point
where the packing runs only slightly warm, with a very
slow drip from the stuffing box. Excess pressure from an
external source can be very destructive to packing. More
pressure is required, however, for abrasive slurries than for
clear liquids. Examination of the leakage will indicate
whether to increase or decrease external pressure. If slurry
is present in the leakage, increase the pressure until only
clear liquid drips from the box. If the drippage is corrosive
or harmful to personnel, it should be collected and piped
away.

Pump
Casing

Fig. 13

24 3409 IOM 11/04

A common error is to open the external piping valve wide
and then control the drippage by tightening the packing
gland. Actually, a combination of both adjustments is
essential to arrive at the optimum condition. The life of
packing and sleeve depends on this careful control more
than any other factor.

MECHANICAL SEALS

The mechanical seal used in an ATEX classified

!

environment must be properly certified.

Mechanical seals are preferred over packing on some
applications because of better sealing qualities and longer
serviceability. Leakage is eliminated when a seal is
properly installed, and normal life is much greater than that
of packing on similar applications. A mechanical shaft seal
is supplied in place of a packed stuffing box when
specifically requested. The change from packing to an
alternate arrangement may be made in the field by
competent service personnel. Conversion parts may be
ordered from your Goulds Pump Sales Representative.

Just as with packing, the mechanical seal chamber must be
supplied, at all times, with a source of clean, clear liquid to
flush and lubricate the seal. The most important
consideration is to establish the optimum flushing pressure
that will keep contaminants from the seal cavity. If this
pressure is too low, fluid being pumped may enter the
stuffing box. If the pressure is too high, excessive seal wear
may result.

Fig. 13 shows the recommended “Controlled Pressure
System” for a mechanical seal. Seal water enters the seal
chamber, lubricates the seal face, and exits into the pump
itself. Positive flow in the seal water line indicates adequate
seal water pressure.

CARTRIDGE SEALS

Follow the appropriate lubrication directions for
mechanical seals given in this section. Most cartridge seals
provide flushing connections on their glands. Use the
cartridge seal gland flushing taps (if provided) for your seal
water connections instead of the stuffing box tap. The
quench taps on the glands (if present) are normally only
used in chemical applications. Consult seal manufacturer’s
literature for more detailed information.

The mechanical seal must have an appropriate seal

!

flush system. Failure to do so will result in excess
heat generation and seal failure.

CYCLONE SEPARATOR

If the fluid being pumped contains sediment and there is no
external, clean water source available to flush the
mechanical seals, a cyclone separator can be used to
remove most of the sediment from the liquid being pumped
so it can be used to flush the seals. The separator is placed
in the seal water piping line and removes the sediment to an
external drain (normally back to the pump suction line).

3

When contaminants are present in the pumpage, an external
source of clean seal water must be supplied. Supply
approximately .25 GPM at a pressure approximately 15 to
20 psig above the suction pressure.

3409 IOM 11/04 25

26 3409 IOM 11/04

OPERATION

PRE-START CHECKS ................................27

PRIMING ........................................28

Flushing .......................................28

Filling ........................................28

STARTING .......................................28

OPERATIONAL CHECKLIST............................29

SHUTDOWN ......................................29

FREEZE PROTECTION ...............................30

FIELD TESTS .....................................30

PRE-START CHECKS

When installing in a potentially explosive

!

environment, ensure that the motor is properly
certified.

Before the initial start of the pump, make the following
inspections:

4

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

9. Assure that pump is full of liquid and all valves are
properly set and operational, with the discharge valve
and the suction valve open. Purge all air from top of
casing.

1. Check alignment between pump and driver. See the
section on alignment for alignment requirements.

All equipment being installed must be properly

!

grounded to prevent unexpected static electric
discharge.

2. Check all connections to motor and starting device with
wiring diagram. Check voltage, phase, and frequency on
motor nameplate with line circuit.

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

4. Turn rotating element by hand to assure that it rotates
freely.

Rotate shaft by hand to ensure it rotates smoothly

!

and there is no rubbing which could lead to excess
heat generation and sparks.

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

6. Check driver lubrication.

Bearings must be lubricated properly in order to

!

prevent excess heat generation, sparks, and
premature failure.

10. Check rotation. Be sure that the driver operates in the
direction indicated by the arrow on the pump casing as
serious damage can result if the pump is operated with
incorrect rotation. Check rotation each time the motor
leads have been disconnected.

Cooling systems such as those for bearing

!

lubrication, mechanical seal systems, etc, where
provided, must be operating properly to prevent
excess heat generation, sparks, and premature
failure.

Check for magnetism on the pump shaft and

!

degauss the shaft if there is any detectable
magnetism. Magnetism will attract ferritic objects to
the impeller, seal and bearings which can result in
excess heat generation, sparks, and premature
failure.

Leakage of process liquid may result in creating an

!

explosive atmosphere. Ensure the materials of the
pump casing, impeller, shaft, sleeves, gaskets, and
seals are compatible with the process liquid.

Leakage of process liquid may result in creating an

!

explosive atmosphere. Follow all pump and seal
assembly procedures.

7. Assure that pump bearings are properly lubricated.

3409 IOM 11/04 27

A build up of gases within the pump, sealing system

!

and/or process piping system may result in an
explosive environment within the pump or process
piping system. Ensure process piping system, pump,
and sealing system are properly vented prior to
operation.

Sealing systems that are not self purging or self

!

venting, such as plan 23, require manual venting
prior to operations. Failure to do so will result in
excess heat generation and seal failure.

PRIMING

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

If the pump is installed with a suction lift, priming must be
done by other methods such as foot valves, ejectors, or by
manually filling the casing and suction line.

$

Under either condition, the pump must be completely
filled with liquid before starting. The pump must not be
run dry in the hope it will prime itself. Serious damage
to the pump may result if it is started dry.

Ensure that pump and systems are free of foreign

!

objects before operating and that objects cannot
enter the pump during operation. Foreign objects in
the pumpage or piping system can cause blockage of
flow which can result in excess heat generation,
sparts, and premature failure.

!CAUTION

FLUSHING

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

FILLING

Vents should be located at the highest point so
entrained gases and air can escape. However, if the
gases are flammable, toxic, or corrosive they should be
vented to an appropriate place to prevent harm to
personnel or other parts of the system. Pipe hangers
and anchors should be

checked to make sure they are properly set to take the
additional weight of the pumpage.

All drains should be closed when filling the system. Filling
should be done slowly so that excessive velocities do not
cause rotation of the pumping elements which may cause
damage to the pump or its driver. The adequacy of the anchors
and hangers may be checked by mounting a dial indicator off
of any rigid structure not tied to the piping and setting the
indicator button on the pump flange in the axial direction of
the nozzle. If the indicator moves, as the filling proceeds, the
anchors and supports are not adequate or set properly and
should be corrected.

STARTING

1. Close drain valves.

2. Open fully all valves in the suction and discharge lines.

3. Turn on seal water to the stuffing box. (If pumped fluid
is dirty or if leaking of air is to be prevented, these
lines should be always left open.)

28 3409 IOM 11/04

4. Prime the pump.

$

If the pump does not prime properly, or loses prime
during start-up, it should be shutdown and the
condition corrected before the procedure is repeated.

CAUTION

5. Start the pump driver (turbines and engines may
require warming up; consult the manufacturer’s
instructions).

6. When the pump is operating at full speed, check to see
that the check valve has opened up. Check valve must
open 5 seconds or less after start-up to prevent damage
to pump by operating at zero flow.

OPERATIONAL CHECKLIST

7. Adjust the liquid seal valves to produce the
recommended pressure for either the mechanical seal
or packed stuffing box.

1. Driver/Pump Rotation

Check rotation each time the motor leads have
been disconnected. Be sure that the driver
operates in the direction indicated by the arrow on
the pump casing. Rough operation and extreme
vibration can result if the pump is operated in the
wrong direction.

2. Stuffing Box Adjustment

Make stuffing box packing gland and lubrication
adjustments.

3. Flow

An accurate measurement of flow rate (volume/time) is
difficult in the field. Venturi meters, flow nozzles,
orifice plates, or timing the draw down in the wet well
are all possible methods. Record any reading for future
reference.

4. Pressure

Check and record both suction and discharge pressure
gauge readings for future reference. Also, record
voltage, amperage per phase, kilowatts if an indicating
wattmeter is available, and pump speed.

5. Temperature

Do not insulate bearing housings as this can result

!

in excess heat generation, sparks, and premature
failure.

Check and record bearing temperatures using a
thermometer. Temperature should not exceed
180° F.

NOTE: Just because bearing housings are too hot to
touch does not mean that they are running too hot for
proper operation.

6. Vibration and Sound

The acceptable vibration level of a centrifugal pump
depends on the rigidity of the pump and the supporting
structure. Recommended values for vibration can vary
between .20 ips (inches per second) velocity to .60 ips
velocity depending on the operating characteristics and
the structure. Refer to the Centrifugal Pump section of
the Hydraulic Institute Standards for a complete
description and charts on various pumps.

Field sound levels are difficult to measure because of
background noise from piping, valves, drivers, gears,
etc. Follow recommendations in the Hydraulic

Institute Standards.

SHUTDOWN

The following steps will take care of most normal
shutdowns of the pump, i.e. maintenance. Make any further
adjustments of process piping, valves, etc., as required. If
the pump is to be removed from service for an extended
period of time, refer to the sections on storage and freeze
protection.

1. Shut down the driver. (Consult manufacturer’s
instructions for special operations.)

2. Close suction and discharge valves.

3409 IOM 11/04 29

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

4. Open drain valves as required.

FREEZE PROTECTION

Pumps that are shut down during freezing conditions
should be protected by one of the following methods.

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

2. Keep fluid moving in the pump and insulate or heat the
pump to prevent freezing.

FIELD TESTS

A typical performance curve for a specific pump can be
obtained from Goulds Pumps. This can be used in
conjunction with a field test, if one is required. Goulds
Pumps tests and curves are based on the Hydraulic Institute
Standards. Any field test must be conducted according to
these Standards.

$

If heat is used to keep the pump from freezing, do not
let the temperature rise above 150° F.

Unless otherwise specifically agreed, all capacity, head,
and efficiencies are based on shop tests when handling
clear, cold, fresh water at a temperature not over 85° F.

The Appendices contains a field test report sheet and some
useful equations which can be used when conducting a
field test.

CAUTION

30 3409 IOM 11/04

PREVENTIVE MAINTENANCE

GENERAL MAINTENANCE AND PERIODIC INSPECTION ..........31

MAINTENANCE TIMETABLE ...........................31

MAINTENANCE OF FLOOD DAMAGED PUMPS ................32

LUBRICATION ....................................32

Grease Lubrication of Bearings ...........................32

Periodic Addition of Grease .............................33

Bearing Temperature ................................33

Oil Lubrication of Bearings .............................33

Coupling Lubrication ................................34

SEALING INFORMATION..............................34

Packing (Non-Asbestos) ...............................34

Mechanical Seals ..................................35

Troubleshooting ...................................36

GENERAL MAINTENANCE AND

PERIODIC INSPECTION

5

The Preventive Maintenance section must be

!

adhered to in order to keep the applicable ATEX
classification of the equipment. Failure to follow
these procedures will void the ATEX classification
for the equipment.

Operating conditions vary so widely that to recommend one
schedule of preventive maintenance for all centrifugal
pumps is not possible. Yet, some sort of regular inspection
must be planned and followed. We suggest a permanent
record be kept of the periodic inspections and maintenance
performed on your pump. This recognition of maintenance
procedure will keep your pump in good working condition
and prevent costly breakdowns.

MAINTENANCE TIMETABLE

INSPECTION INTERVALS

Inspection intervals should be shortened

!

appropriately if the pumpage is abrasive and/or
corrosive, or if the environment is classified as
potentially explosive.

EVERYMONTH

Check bearing temperature with a thermometer, not by hand.
If bearings are running hot (over 180° F), it may be the result
of too much or too little lubricant. If changing the lubricant

One of the best results to follow in the proper maintenance
of your centrifugal pump is to keep a record of actual
operating hours. Then, after a predetermined period of
operation has elapsed, the pump should be given a
thorough inspection. The length of this operating period
will vary with different applications, and can only be
determined from experience. New equipment, however,
should be examined after a relatively short period of
operation. The next inspection period can be lengthened
somewhat. This system can be followed until a maximum
period of operation is reached which should be considered
the operating schedule between inspections.

and/or adjusting to proper level does not correct the condition,
disassemble and inspect the bearings. Lip seals bearing on the
shaft may also cause the housing to run hot. Lubricate lip seals
to correct this condition.

EVERY3 MONTHS

Check the oil on oil lubricated units. Check grease lubricated
bearings for saponification. This condition is usually caused
by the infiltration of water or other fluid past the bearing shaft
seals and can be noticed immediately upon inspection, since it
gives the grease a whitish color. Wash out the bearings with a

3409 IOM 11/04 31

clean industrial solvent and replace the grease with the proper
type as recommended.

EVERY6 MONTHS

Check the packing and replace if necessary. Use the grade
recommended. Be sure the seal cages are centered in the
stuffing box at the entrance of the stuffing box piping
connection.

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

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

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

EVERY YEAR

Remove the upper half of the casing. Inspect the pump
thoroughly for wear, and order replacement parts if
necessary.

Check wear ring clearances. Replace when clearances
become three (3) times their normal clearance or when a
significant decrease in discharge pressure for the same flow
rate is observed.

See Engineering Data Section in the Appendix for standard
clearances.

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

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

NOTE: The above timetable is based on the assumption that
after startup, the unit has been constantly monitored and
such a schedule was found to be consistent with operation, as
shown by stable readings. Extreme or unusual applications
or conditions should be taken into consideration when
establishing the maintenance intervals.

MAINTENANCE OF FLOOD DAMAGED PUMPS

The servicing of centrifugal pumps after a flooded
condition is a comparatively simple matter under normal
conditions.

Bearings are a primary concern on pumping units. First,
dismantle the frame, clean and inspect the bearings for any
rusted or badly worn surfaces. If bearings are free from rust
and wear, reassemble and relubricate them with one of the
recommended lubricants. Depending on the length of time
the pump has remained in the flooded area, it is unlikely
that bearing replacement is necessary; however, in the
event that rust or worn surfaces appear, it may be necessary
to replace the bearings.

Next, inspect the stuffing box, and clean out any foreign matter
that might clog the box. Packing that appears to be worn, or no
longer regulates leakage properly should be replaced.
Mechanical seals should be cleaned and thoroughly flushed.

Couplings should be dismantled and thoroughly cleaned.
Lubricate the coupling with one of the coupling manufacturer’s
recommended lubricants where required.

Any pump that is properly sealed at all joints and connected to
both the suction and discharge should exclude outside liquid.
Therefore, it should not be necessary to go beyond the bearings,
stuffing box, and coupling when servicing the pump after flood
damage.

LUBRICATION

provided the pump has been stored in a clean, dry place prior to

Bearings must be lubricated properly in order to prevent

!

excess heat generation, sparks, and premature failure.

GREASE LUBRICATIONOF
BEARINGS

Grease lubricated ball bearings are packed with grease at the
factory and ordinarily will require no attention before starting,

its first operation. The bearings should be watched the first hour
or so after the pump has been started to see that they are operating
properly.

A lithium based NLGI-2 grade grease should be used for
lubricating bearings where the ambient temperature is above -20°
F. Grease lubricated bearings are packed at the factory with
Mobilux EP No. 2 grease. Other recommended greases are

32 3409 IOM 11/04

Texaco Multifak EP-2 and Shell Alvania EP-2.

Greases made from animal or vegetable oils are not
recommended due to the danger of deterioration and
forming of acid. Do not use graphite.

In greasing anti-friction bearings, the use of high pressure
equipment is not only unnecessary, but is actually
undesirable unless used with great care. High pressure may
damage the bearings or seals, cause unnecessary loss of
grease, create a danger of overheating due to over greasing,
and produce unsightly conditions around the bearing.
Excess grease is the most common cause of overheating.
Adequate lubrication is assured if the level of grease is
maintained at about the capacity of the bearing and 1/3 to
1/2 of the cavity between the bearing and grease fitting. Any
greater amount will, as a rule, be discharged by the seal or vent
and be wasted.

The importance of proper lubrication cannot be over
emphasized. Lubrication frequency depends upon the speed,
size and type of bearing, and operating temperature or
environmental conditions. Generally, the smaller the bearing
and faster the speed, the more frequent the interval for
relubrication with grease. It is recommended that a certain
amount of grease be added at intervals of three to six months to
replace the small quantity of grease lost between grease flushing
intervals. For average bearing housing designs, one (1) ounce
of grease will be sufficient at these intervals. For larger or
smaller bearing housings this amount may have to be adjusted.

BEARING TEMPERATURE

Normally the maximum desirable operating temperature for ball
bearings is 180° F. Special designs may have higher limits.
Should the temperature of the bearing frame rise above the limit,
the pump should be shut down to determine the cause. A
bearing frame which feels hot to the touch of the hand is not
necessarily running hot. Check with an accurate temperature
measuring device to be sure.

OIL LUBRICATION OF BEARINGS

Oil lubrication on 3409 pumps is considered optional. Oil
lubricated pumps are installed with Trico oilers (See Fig.

14). The oilers keep the oil level in the housings constant at
proper level.

After the pump has been installed, flush the housing to
remove dirt, grit, and other impurities that may have
entered the bearing housing during shipment or installation;
then refill the housing with proper lubricant. (The housing
must be filled using the Trico oiler.) The oil level will be
maintained by the Trico oiler. (See the SERVICE section
for the proper instructions.)

5

Unfortunately, there is not a grease available which will not
harden over time and become less suitable for its purpose due to
oxidation. Therefore, it is good practice to remove all the old
grease about once a year and thoroughly clean the bearings. This
should be done during major overhauls. After gaining
experience with each individual pump and its operating
characteristics, the relubrication and flushing intervals may be
adjusted accordingly. Keep good records and add grease at
regular intervals. Then adjustments can be made after the first
overhaul, if necessary.

PERIODIC ADDITION OF GREASE

Grease lubricated ball bearings are packed with grease at the
factory. Store the pump in a clean, dry place prior to its first
operation.

If one is uncertain about the amount of grease in a bearing at
relubrication intervals, the safe rule is to add grease slowly (one
ounce at a time) as the bearing operates (if this is safe).
Remember, a ball or roller bearing in most applications is
assured of adequate lubrication if the level of grease is
maintained at about the capacity of the bearing and 1/3 to 1/2 of
the cavity between the bearing and grease fitting. Any greater
amount will, as a rule, be discharged by the seals or vent and be
wasted. Excess grease is the most common cause of overheating
of the bearings. Remove vent plugs for the first 24 hours of
operation after regreasing.

Fig. 14

A Mobil Oil, DTE Medium, or equal, meeting the following
specification will provide satisfactory lubrication. Similar
oils can be furnished by all major oil companies. It is the
responsibility of the oil vendor to supply a suitable lubricant.

(1) Saybolt viscosity at 100° F ........... 215SSU-240SSU

(2) Saybolt viscosity at 210° F ................ .49SSU

(3)Viscosityindex,minimum................... 95

(4)APIgravity........................ .28-33

(5)Pourpoint,maximum................... +20°F

(6)Flashpoint,minimum................... 400° F

(7) Additives ...............Rust&OxidationInhibitors

(8)ISOviscosity......................... 46

NOTE: Oils from different suppliers should not be
mixed. Engine oils are not recommended.

3409 IOM 11/04 33

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

In installations with moderate temperature changes, low
humidity, and a clean atmosphere, the oil should be changed
after approximately 1000 hours of operation. The oil should be
inspected at this time to determine the operating period before
the next oil change. Oil change periods may be increased up to
2000-4000 hours based on an 8000 hour year. Check the oil
frequently for moisture, dirt or signs of “breakdown,”
especially during the first 1000 hours.

$

Do not over oil; this causes the bearings to run hot.
The maximum desirable bearing housing operating
temperature for all ball bearings is 180° F. Should the
temperature of the bearing frame exceed 180° F
(measured by thermometer) shut down pump to
determine the cause.

CAUTION

COUPLING LUBRICATION

Grid or gear tooth couplings (Falk Grid Steelflex or Falk
Crowned Tooth coupling for instance) are initially lubricated
with Falk Long Term Grease (LTG) and do not require
relubrication for up to three years. If coupling leaks grease, or
is exposed to extreme temperatures or excessive moisture,
more frequent lubrication may be required.

Use coupling manufacturer’s recommended grease to provide
trouble free performance.

Flexible couplings (Wood’s Sure-Flex or Falk Torus coupling
for instance) provide smooth transmission of power. There is
no rubbing action of metal against rubber to cause wear.
Couplings are not affected by abrasives, dirt or moisture. This
eliminates the need for lubrication or maintenance, and
provides clean and quiet performance.

If other types of couplings are used, follow maintenance
instructions of coupling manufacturer.

SEALING INFORMATION

PACKING (NON-ASBESTOS)

On packed pumps the packing is installed prior to shipment. All
packings used are the highest grade material. Before pump is put
into operation check the condition of the packing. If pump is
installed within sixty (60) days after shipment the packing will be
in good condition with a sufficient supply of lubrication. If pump
is stored for a longer period it may be necessary to repack the
stuffing box. In all cases, however, we recommend an inspection
of the packing before pump is started.

The standard 3409 pump packing is made from braided acrylic
yarn impregnated with graphite.

A soft, well-lubricated packing reduces stuffing box resistance
and prevents excessive wear on the shaft or shaft sleeve. Many
brands of packing on the market have the desired qualities.
Standard packing is John Crane Style 1340, or equal.

When a pump with fiber packing is first started it is advisable to
have the packing slightly loose without causing an air leak. As the
pump runs in, gradually tighten the gland bolts evenly. The gland
should never be drawn to the point where packing is compressed
too tightly and no leakage occurs. This will cause the packing to
burn, score the shaft sleeve and prevent liquid from circulating
through the stuffing box cooling the packing. The stuffing box is
improperly packed or adjusted if friction in the box prevents
turning the rotating element by hand. A properly operated stuffing
box should run lukewarm with a slow drip of sealing liquid. After
the pump has been in operation for some time, and the packing
has been in operation for some time, and the packing has been

completely run-in, drippage from the stuffing boxes should be at
least 40 to 60 drops per minute. This will indicate proper packing
and shaft sleeve lubrication and cooling.

NOTE: Eccentricity of the shaft or sleeve through the
packing could result in excess leakage that cannot be
compensated for. Correction of this defect is very important.

Packing should be checked frequently and replaced as service
indicates. Six months might be a reasonable expected life,
depending on operating conditions. It is impossible to give any
exact predictions. A packing tool should be used to remove all old
packing from the stuffing box. Never reuse old and lifeless
packing or merely add some new rings. Make sure the stuffing
box is thoroughly cleaned before new packing is installed. Also
check the condition of the shaft or sleeve for possible scoring or
eccentricity, make replacements where necessary.

New packing (non-asbestos) should be placed carefully into the
stuffing box. If molded rings are used, the rings should be opened
sideways and the joints pushed into the stuffing box first. The
rings are installed one at a time, each ring seated firmly and the
joints staggered at about a 90° rotation from each preceding joint.

If coil packing is used, cut one ring to accurate size with either a
butt or mitered joint. An accurately cut butt joint is superior to a
poor fitting mitered joint. Fit the ring over the shaft to assure
proper length. Then remove and cut all other rings to the first
sample. When the rings are placed around the shaft a tight joint
should be formed. Place the first ring in the bottom of the stuffing

34 3409 IOM 11/04

box. Then install each succeeding ring, staggering the joints as
described above, making sure each ring is firmly seated.

Four important rules which should always be followed for
optimum seal life are:

If your pump is supplied with seal cages (optional) make
sure the seal cages are properly located in the stuffing
boxes under the sealing water inlets. The function of the
seal cage is to establish a liquid seal around the shaft,
prevent leakage of air through the stuffing box and
lubricate the packing. If it is not properly located it serves
no purpose.

MECHANICAL SEALS

General instructions for operation of the various
mechanical sealing arrangements are included below. It is
not feasible to include detailed instructions for all
mechanical seals in this booklet because of the almost
unlimited number of possible combinations and
arrangements. Instead, seal manufacturer’s instructions will
be included as a separate supplement to this book, where
required.

a. Mechanical seals are precision products and should be

treated with care. Use special care when handling
seals. Clean oil and clean parts are essential to prevent
scratching the finely lapped sealing faces. Even light
scratches on these faces could result in leaky seals.

b. Normally, mechanical seals require no adjustment or

maintenance except routine replacement of worn or
broken parts.

1. Keep the seal faces as clean as possible.

2. Keep the seal as cool as possible.

3. Assure that the seal always has proper lubrication.

4. If seal is lubricated with filtered fluid, clean filter
frequently.

5

c. A mechanical seal which has been used should not be

put back into service until the sealing faces have been
replaced or relapped. (Relapping is generally
economical only in seals two inches in size and above.)

3409 IOM 11/04 35

TROUBLESHOOTING

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

Problem Item Probable Cause Remedy

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

Check for leaks in suction pipe joints and fittings; vent casing to remove
accumulated air. Check mechanical seal or packing.

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

Check with factory to see if a larger impeller can be used; otherwise, cut pipe losses
or increase speed — or both, as needed. But be careful not to seriously overload
driver.

Check whether motor is directly across-the-line and receiving full voltage.
Frequency may be too low. Motor may have an open phase.

Check motor rotation with directional arrow on pump casing. If rotation is correct
with arrow, check the relationship of the impeller with casing.
(This will require removing casing upper half.)

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

If liquid pumped is water or other non-explosive and explosive gas or dust
is not present, test flanges for leakage with flame or match. For such
liquids as gasoline, suction line can be tested by shutting off or plugging
inlet and putting line under pressure. A gauge will indicate a leak with a
drop of pressure.

Replace packing and sleeves if appropriate or increase seal lubricant pressure to
above atmosphere.

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

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

Inspect impeller and wear rings. Replace if damaged or vane sections
are badly eroded or if wear ring clearance is 3 times normal.

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

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

Symptoms are an overloaded driver and about one third rated capacity from pump.
Compare rotation of motor with directional arrow on pump casing. If rotation is cor
rect with arrow, impeller may have to be turned 180°.
(See CHANGING ROTATION)

Check to see if suction and discharge valves are fully open. Dismantle pump and in
spect passages and casing. Remove obstruction.

May be possible to over rate pump to a point where it will provide adequate pressure de
spite condition. Better provide gas separation chamber on
suction line near pump and periodically exhaust accumulated gas. See item 17.

No Liquid
Delivered

Not Enough
Liquid
Delivered

Not Enough
Pressure

2 Loss of prime.

Suction lift too high

3

(a negative suction gauge reading).

4 System static head too high.

5 Speed to low.

6 Wrong direction of rotation.

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

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

9 Impeller completely plugged. Dismantle pump and clean impeller.

System head or required discharge head

10

too high.

11 Air leaks in suction piping.

12 Air leaks in stuffing box.

13 Speed too low. See item 5.

14 Discharge head too high. See item 10.

15 Suction lift too high. See item 3.

16 Impeller partially plugged. See item 9.

Cavitation; insufficient NPSHA

17

(Net Positive Suction Head Available).

18 Defective Impeller and/or wear rings.

19 Foot valve too small or partially obstructed.

20 Suction inlet not immersed deep enough.

21 Wrong direction of rotation.

22 System head too high. See item 4.

23 Defective mechanical seal. Repair or replace seal.

24 Speed too low. See item 5.

25 Air leaks in suction piping or stuffing box. See item 11.

26 Mechanical defects. See item 18.

27 Vortex at suction inlet. See item 20.

28 Obstruction in liquid passages.

29 Air or gases in liquid.

-

-

-

-

36 3409 IOM 11/04

Problem Item Probable Cause Remedy

Pump
Operates
For a Short
Time, Then
Stops

Pump
Takes
Too Much
Power

30 Insufficient NPSHA. See item 17.

31 System head too high. See items4&10.

Head lower than rating; thereby pumping too much

32

liquid.

33 Cavitation. See item 17.

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

35 Suction inlet not immersed. See item 20.

Liquid heavier (in either viscosity or specific

36

gravity) than allowed for.

37 Wrong direction of rotation. See item 6.

38 Stuffing box glands too tight.

Casing distorted by excessive strains from

39

suction or discharge piping.

Shaft bent due to damage — through shipment, op

40

eration, or overhaul.

41 Mechanical failure of critical pump parts.

42 Misalignment. Realign pump and driver.

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

44 Electrical defects.

Mechanical defects in turbine, engine or other type

45

of drive exclusive of motor.

Machine impeller’s O.D. to size advised by factory, or reduce speed.

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

Release gland pressure. Tighten reasonably. If sealing liquid does
not flow while pump operates, replace packing.

Check alignment. Examine pump for rubbing between impeller and
casing. Replace damaged parts. Re-pipe pump.

Check deflection of rotor by turning on bearing journals. Total

­indicator run-out should not exceed .002" on shaft and .004"

on impeller wearing surface.

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

The voltage and frequency of the electrical current may be lower than
that for which motor was built, or there may be defects in motor. The
motor may not be ventilated properly do to a poor location.

If trouble cannot be located consult factory.

5

3409 IOM 11/04 37

38 3409 IOM 11/04

DISASSEMBLY & REASSEMBLY

PROCEDURES.....................................39

CHANGING ROTATION ...............................40

DISMANTLING (PUMP WITH PACKING) ....................41

ASSEMBLY (PUMP WITH PACKING).......................42

Pumps With Grease Lubrication...........................43

Pumps With Oil Lubrication.............................43

DISMANTLING (PUMP WITH MECHANICAL SEALS).............45

ASSEMBLY WITH MECHANICAL SEALS ....................46

Pumps with Grease Lubrication ...........................47

Pumps with Oil Lubrication .............................47

ADJUSTABLE WEAR RINGS ............................49

Adjustment......................................49

Disassembly and Reassembly ............................49

OIL LUBRICATED BEARINGS ...........................50

VERTICAL UNITS ..................................51

Upper Casing Half Removal.............................51

Rotating Element Removal .............................52

Reassembly of Rotating Element ..........................52

Replacing Upper Casing Half ............................53

Complete Pump Removal ..............................53

LIMITED END FLOAT COUPLINGS........................54

6

PROCEDURES

The procedures outlined in this section cover the
dismantling and reassembly of two different types of 3409
pump construction.

A. 3409 pump with packing.

B. 3409 pump with mechanical seals.

Each procedure provides the step-by-step instructions for
dismantling and then reassembling the pump, depending
upon the type of shaft seal used.

When working on the pump, use accepted mechanical
practices to avoid unnecessary damage to parts. Check
clearances and conditions of parts when pump is
dismantled and replace if necessary.

Steps should usually be taken to restore impeller and casing
ring clearance when it exceeds three times the original
clearance.

If your pump has adjustable wear rings, see Adjustable
Wear Rings in the Disassembly & Reassembly Section.

$

For pumps in a vertical configuration (half pedestal
or full pedestal), please follow the instructions for the
disassembly and reassembly in the Vertical Units
(Half and Full Pedestal) Section.

CAUTION

3409 IOM 11/04 39

CHANGING ROTATION

3409 centrifugal pumps can be operated clockwise or
counterclockwise when viewed from the coupling end of
the pump (Fig. 15). If you wish to reverse the suction and
discharge nozzles; i.e., change rotation, this can be
accomplished with the same pump as follows:

1. Remove the impeller from the shaft, turn it 180° and
replace it on the shaft. (Follow the disassembly
procedures given in this manual.)

2. With the rotating element out of the casing, remove the
casing from the baseplate and turn 180°. (Factory
baseplates are drilled for both rotations.)

3. Set the rotating element back in the casing and
reassemble the pump.

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

4. Reassemble the pump and realign the coupling as
called for in the alignment instructions.

5. The rotation of the motor must be changed by
switching motor leads.

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

$

Check motor fan to make sure it is bi-directional. If
not, motor fan will have to be turned around or
replaced. Failure to do this could cause motor to run
hot.

CAUTION

Fig. 15

40 3409 IOM 11/04

Pump

Size

6x10-22 26

8x12-22 26

8x12-27 44

10x14-20S 26

12x16-23 26

14x16-17 24

14x18-23 32

14x18-28 34

10 x14-20L 26 16.60

Qty. Of

Item Nos.

426 & 426A

DISMANTLING (PUMP WITH PACKING)

Dimension

A

13.508x12-21 26

15.81

6

Fig. 16

! WARNING

s

Prior to working on the pump, the power source
should be disconnected with lockout provisions so the
power cannot be re- energized to the motor. Close
isolating and discharge valves. Failure to follow these
instructions could result in property damage, severe

(107) from each stuffing box.

5. Remove all casing main joint cap screws (426 &
426A) and dowels (469G). Use slot in casing main
joint and separate the casing halves with a pry bar.
Lift upper half casing (100) by cast lugs.

personal injury, or death. (See Cross Sectional view in

4. Remove gland bolts (353B), washers (354), and gland

the Appendices.)

6. Remove packing (106) and seal cage (105) from each
stuffing box.

1. Drain pump by opening vent plug (408G) and
removing drain plugs (408G) on suction and discharge
nozzle.

7. Remove cap screws (372U) which hold bearing
housings (134) to the casing and lift rotating element
(See Fig. 17) out of lower half casing (100). Rotating

2. Remove coupling guard and separate the coupling to
disconnect the pump from the driver.

element may now be moved to a suitable working
location.

3. Remove seal lines (102), if supplied.

3409 IOM 11/04 41

$

Do not reuse ball bearings.

11. Remove bearing covers (109 & 119) and push bearing
isolators out of bearing covers and coupling end
bearing housing (332A & 333A).

CAUTION

Fig. 17

8. Pull coupling half and key (400) off shaft (122).

NOTE: A spare rotating element can be installed at
this point.

9. Remove cap screws (371C) from bearing covers (109
& 119).

10. Remove bearing housings (134), locknut (136), and
lockwasher (382). Mount bearing puller and remove
bearings (168 & 410). Remove thrust washer (535)
and snap rings (276).

NOTE: Locknut, lockwasher, and thrust washer are
not used on inboard bearing.

ASSEMBLY (PUMP WITH PACKING)

Packed stuffing boxes are not allowed in an ATEX

!

classified environment.

All bearings, O-rings, seals, gaskets, impeller rings, and casing
wear rings should be replaced with new parts during assembly.
All reusable parts should be cleaned of all foreign matter before
reassembling. The main casing joint gasket should be made
using the lower half as a template. Lay the gasket material on
the casing joint and mark it by pressing it against the edges of
the casing. Trim the gasket so that it is flush with the inside
edges of the casing.

NOTE: Precut casing gaskets (351D & 351S) can be
ordered to minimize the amount of trimming.

12. Remove casing rings (127) from impeller (101).

13. Remove set screw (222B) from shaft nuts. Remove
shaft nuts (124), O-rings (497), sleeves (126), sleeve
gaskets (428), and impeller (101).

NOTE: Apply heat uniformly to the shaft sleeve to
loosen the sealant between the shaft and sleeve. DO
NOT HEAT ABOVE 275° F. To further assist in
removing the sleeves, hold the shaft vertically and tap
it on a block of wood. The impeller weight should
force both the impeller and sleeve from the shaft.

14. See Adjustable Wear Rings Section if pump is
equipped with adjustable rings.

NOTE: For impellers with replaceable rings —
remove the rings (142) by cutting the rings with a cold
chisel. (See Fig. 18)

4. Slide sleeve gaskets (428) onto shaft and against hubs
of impeller.

5. Slide sleeves (126) onto shaft.

6. Place the sleeve O-ring (497) onto the shaft, into the
sleeve counterbore. Verify that Dimension “A”
(Fig. 16) is maintained, then using a pin spanner wrench
and hammer, securely tighten the shaft sleeve nuts
(124). Then, drill a shallow recess in the shaft through
the set screw hole in each of the shaft sleeve nuts. Lock
each shaft sleeve nut in position with cup point set
screws (222B). (See Fig. 19) A low strength sealant,
such as Loctite 271, can be used to retain set screws.

1. Place impeller key (178) in shaft (122).

2. Check the impeller (101) and casing (100) to
determine the correct impeller rotation (See
Fig. 15) and locate the impeller on the shaft per
dimension “A”. (See Fig. 16)

NOTE: For impellers with replaceable rings, heat each
new ring (142) and slide it onto the impeller. Hold rings
against the impeller shoulder until they cool. (See Fig. 19

3. Place both shaft sleeve keys (401) on shaft (122).

42 3409 IOM 11/04

(126)

SLEEVE

(142)

IMPELLER RING

(127)

CASING RING

$

Do not exceed 275° F.

CAUTION

LOCKING PIN

(445A)

CASING

(100)

IMPELLER

(101)

Fig.18

$

These are precision, high quality bearings. Exercise care
at all times to keep them clean and free of foreign matter.

9. Press inboard bearing isolators (333A) in each bearing
cover. Install gaskets (360) on each bearing cover.

10. Slide bearing covers (109 & 119) on the shaft. Install snap
rings (276). Install thrust washer (535) on the outboard
end.

NOTE: For ease of assembly and protection of rubber
parts while sliding rubber parts onto shaft, cover O-ring
groove, keyways, and threads with electrical tape.

NOTE: Inboard bearing cover (119) is approximately 1/4
inch less in width than the outboard bearing cover (109).
This is the only dimensional difference.

11. Press heated bearing (168 & 410) on shaft against snap
ring or thrust washer. Install locknut (136) and lockwasher
(382) on outboard end. Make certain locknut is secured
and then bend over tab on lockwasher.

CAUTION

PUMPS WITH GREASE LUBRICATION

12. Cool bearings at room temperature and coat with 2 or 3
ounces of a recommended grease.

PUMPS WITH OIL LUBRICATION

Refer to Oil Lubricated Bearings Section for installation of
oil lubricated parts.

6

Fig. 19

7. Assemble casing rings (127). (See Adjustable Wear
Ring Section, if required.)

8. Start heating bearings (168 & 410) so that they will be
ready when called for in step 11. Use dry heat from
induction heat lamps or electric furnace, or a 10-15%
soluble oil and water solution.

13. Press outboard bearing isolator (332A) in coupling end
bearing housing.

14. Slide bearing housings (134) onto shaft (122) over
bearings (168 & 410).

15. Assemble bearing cover to bearing housing with two cap
screws (371C).

16. Replace pump coupling half and key (400).

17. Assemble rotating element in lower half casing (100).
Correctly locate casing ring pins (445A) in casing main
joint slot.

NOTE: Sliding inboard bearing housing toward coupling
prior to assembling rotating element in casing will ease
assembly.

18. Bolt outboard bearing housing in place. Be sure that both
housings are seated properly in lower half casing.

19. Bolt inboard bearing housing in place.

3409 IOM 11/04 43

20. Clean the gasket surfaces of the casing. Apply Scotch
3M-77 spray adhesive or equivalent to the lower half of the
casing.

25. If supplied, assemble seal water lines (102) to stuffing box
and casing. Seal water lines should be piped to the tapped
holes nearest impeller (See Fig. 16).

21. Within one minute of spraying, set the gaskets
(351D & 351S) in place on the lower half casing, align the
holes in the gaskets with the holes in the casing and press
the gaskets firmly against the lower half casing face in the
area coated by the adhesive.

22. Lower upper half casing (100) into place (See
Fig. 20) and locate using the taper dowels (469G) and
install casing main joint bolts (426 & 426A). The casing
joint bolts should be tightened to the following torques: 300
ft-lb minimum for .75"-10 Ferry Cap Countr-bor screws
(Grade 8), 400 ft-lb minimum for 1.0"-8 Ferry Cap
Countr-bor screws (Grade 8). Bolt torquing pattern is
shown in Fig. 39. The number of casing bolts varies with
the size of the pump. (See Fig. 16) Before tightening bolts,
be sure taper dowels are seated properly in reamed holes.

NOTE: Torquing bolts to proper values in proper
sequence is essential in obtaining proper gasket
compression so no leakage can occur at main joint.

26. Check coupling alignment and redowel if necessary.

Fig. 21

Fig. 22

Fig. 20

$

Double check rotation of pump before installing the upper
half casing. (Refer to Fig. 15)

23. Rotate shaft by hand to assure that it turns smoothly and is
free from rubbing and binding.

24. Cut full rings of 5/8 inch square packing so that ends butt,
leaving no gap between packing and casing. Install three rings
of packing (106) and tap fully to bottom of both stuffing boxes
(See Fig. 21). Stagger joints of each ring of packing at least
90°. Install seal cage (105) (if this optional part was supplied)
and be sure that it will line up with seal water inlet when
packing is compressed. Install remaining two rings of packing
(three rings if no seal cage present) with joints staggered.
Assemble glands (107) square with stuffing box and pull up
tight. Then loosen gland bolts (353B) to permit packing to
expand, and retighten finger tight. Final adjustment of gland
bolts must be done when pump is running. Allow 30 minutes
between adjustments (See Fig. 22).

CAUTION

44 3409 IOM 11/04

Pump

Size

6x10-22 26

8x12-22 26

8x12-27 44

10x14-20S 26

12x16-23 26

14x16-17 24

14x18-23 32

14x18-28 34

10 x14-20L 26 16.60

Qty. of

Item nos.

426 &
426A

Dimension

A

13.508x12-21 26

15.81

Fig. 23

DISMANTLING (PUMP WITH MECHANICAL SEALS)

6

! WARNING

s

Prior to working on the pump, the power source
should be disconnected with lockout provisions so the
power cannot be re- energized to the motor. Close
isolating and discharge valves. Failure to follow these
instructions could result in property damage, severe
personal injury, or death (See Cross Sectional View in
the Appendices).

1. Drain pump by opening vent plug (408G) and
removing drain plugs (408G) on suction and discharge
nozzle.

2. Remove coupling guard and separate the coupling to
disconnect the pump from the driver.

3. Remove seal lines (102), if supplied.

4. Remove gland bolts (353B) and slide gland (250) away
from casing.

5. Remove all casing main joint cap screws (426 &
426A) and dowels (469G). Use slot in casing main

joint and separate the casing halves with a pry bar.
Lift upper half casing (100) by cast lugs.

6. Remove cap screws (372U) which hold bearing
housings (134) to the casing and lift rotating element
out of lower half casing (100). Rotating element may
now be moved to a suitable working location.

7. Pull coupling half and key (400) off shaft (122).

NOTE: A spare rotating element can be
installed at this point.

8. Remove cap screws from bearing covers (109 & 119).

9. Remove bearing housings (134), locknut (136), and
lockwasher (382). Mount bearing puller and remove
bearings (168 & 410). Remove thrust washer (535)
and snap rings (276).

NOTE: Locknut, lockwasher, and thrust washer are not
used on inboard bearing.

3409 IOM 11/04 45

$

Do not reuse ball bearings.

10. Remove bearing covers (109 & 119) and push bearing
isolators (332A & 333A) out of bearing covers and
coupling end bearing housing.

11. Remove glands (250). Loosen set screws and remove
mechanical seal head assembly (383). Press mechanical
seal seats (383) from glands.

12. Remove casing rings (127) from impeller (101).

13. Remove set screw (222B) from shaft nuts. Remove shaft
nuts (124), O-rings (497), sleeves (126), sleeve gasekts
(428), and impeller (101).

NOTE: Apply heat uniformly to the shaft sleeve to loosen
the sealant between the shaft and sleeve. DO NOT HEAT
ABOVE 275° F. To further assist in removing the sleeves,
hold the shaft vertically and tap it on a block of wood. The
impeller weight should force both the impeller and sleeve
from the shaft.

14. Refer to Adjustable Wear Ring Section if pump is equipped
with adjustable rings.

NOTE: For impellers with replaceable rings - remove the
rings (142) by cutting the rings with a cold chisel.

CAUTION

(126)

Sleeve

(445A)

LOCKING PIN

(142)

IMPELLER RING

(100)

CASING

(127)

CASING

RING

(101)

IMPELLER

Fig. 24

ASSEMBLY (PUMP WITH MECHANICAL SEALS)

All bearings, O-rings, seals, gaskets, impeller rings, and casing
wear rings should be replaced with new parts during assembly.
All reusable parts should be cleaned of all foreign matter before
reassembling. The main casing joint gasket should be made
using the lower half as a template. Lay the gasket material on
the casing joint and mark it by pressing it against the edges of
the casing. Trim the gasket so that it is flush with the inside
edges of the casing.

NOTE: Precut casing gaskets (351D & 351S) can be
ordered to minimize the amount of trimming.

1. Place impeller key (178) in shaft (122).

2. Check the impeller (101) and casing (100) to determine the
correct impeller rotation (See
Fig. 15) and locate the impeller on the shaft per dimensiton
“A”. (See Fig. 23)

NOTE: For impellers with replaceable rings, heat each
new ring (142) and slide it onto the impeller. Hold
rings against the impeller shoulder until they cool. (See
Fig. 24)

3. Place both shaft sleeve keys (401) on shaft (122).

4. Slide sleeve gaskets (428) onto shaft and against hubs of
impeller.

5. Slide sleeves (126) onto shaft.

6. Place the sleeve O-ring (3-914-9) onto the shaft, into
the sleeve counterbore. Verify that Dimension “A”
(Fig. 23) is maintained, then using a pin spanner
wrench and hammer, securely tighten the shaft sleeve
nuts (3-015-9). Then, drill a shallow recess in the
shaft through the set screw hole in each of the shaft
sleeve nuts. Lock each shaft sleeve nut in position
with cup point set screws (3-902-9). (See Fig. 29) A
low strength sealant, such as Loctite 271, can be used
to retain set screws.

46 3409 IOM 11/04

Fig. 25

7. Assemble casing rings (127). (See Adjustable Wear Ring
Section, if required.)

8. Install stationary seats (383) into the glands (250) with
lapped surface facing outward.

NOTE: Do not scratch or damage seal faces during
assembly. Stationary seat must bottom squarely in
gland.

9. Apply fine coat of silicon grease or equivalent to shaft
sleeve, and slide seal head assembly (383) over sleeve.
(See Fig. 26) If seal is a John Crane Type 8, set seal to
approximate dimension shown in Fig. 28 and tighten
set screws. Next, install O-rings (412G) onto glands
(250) and install glands on the shaft.

$

Do not use petroleum based products for installing
mechanical seal head as it may attack the rubber
elastomers.

10. Start heating bearings (168 & 410) so that they will be
ready when called for in step 13. Use dry heat from
induction heat lamps or electric furnace, or a 10-15%
soluble oil and water solution.

! CAUTION

$

Do not exceed 275° F.

$

These are precision, high quality bearings. Exercise
care at all times to keep them clean and free of foreign
matter.

CAUTION

CAUTION

Fig. 26

11. Press inboard bearing isolators (333A) in each bearing
cover. Install gaskets (360) on each bearing cover.

12. Slide bearing covers (109 & 119) on the shaft. Install snap
rings (276). Install thrust washer (535) on the outboard
end.

NOTE: For ease of assembly and protection of rubber
parts while sliding rubber parts onto shaft, cover O-ring
groove, keyways, and threads with electrical tape.

NOTE: Inboard bearing cover (119) is approximately 1/4
inch less in width than the outboard bearing cover (109).
This is the only dimensional difference.

13. Press heated bearing (168 & 410) on shaft against snap
ring or thrust washer. Install locknut (136) and lockwasher
(382) on outboard end. Make certain the locknut is secured
and then bend over tab on lockwasher.

PUMPS WITH GREASE LUBRICATION

14. Cool bearings at room temperature and coat with 2 or 3
ounces of a recommended grease.

PUMPS WITH OIL LUBRICATION

See Oil Lubricated Bearings Section for installation of oil
lubricated parts.

15. Press outboard bearing isolator (332A) in coupling end
bearing housing.

16. Slide bearing housings (134) over bearings (168 & 410).

17. Assemble bearing cover to bearing housing with two cap
screws (371C).

6

18. Replace pump coupling half and key (400).

19. Assemble rotating element in lower half casing (100).
Correctly locate casing ring pins (445A) in casing main
joint slot.

NOTE: Sliding inboard bearing housing toward coupling
prior to assembling rotating element in casing will ease
assembly.

3409 IOM 11/04 47

20. Bolt outboard bearing housing in place. Be sure that both
housings are seated in lower half casing.

21. Bolt inboard bearing housing in place. If seal is a John
Crane Type 8, set seal to dimensional shown in Fig. 27
and tighten set screws.

Fig. 27

22. Clean the gasket surfaces of the casing. Apply Scotch
3M-77 spray adhesive or equivalent to the lower half
of the casing.

$

Double check rotation of pump before installing the
upper casing (Refer to Fig. 15).

25. Rotate shaft by hand to assure that it turns smoothly and
is free from rubbing and binding.

26. Bolt glands (250) to casing with gland bolts (353B).

27. Assemble seal water lines (102) to stuffing box and
casing. Seal water lines should be piped to the tapped
holes nearest bearings (See Fig. 23).

28. Check coupling alignment and redowel if necessary.

CAUTION

23. Within one minute of spraying, set the gaskets (351D &
351S) in place on the lower half casing, align the holes in
the gaskets with the holes in the casing and press the
gaskets firmly against the lower half casing face in the
area coated by the adhesive.

24. Lower upper half casing (100) into place (See
Fig. 28) and locate using the taper dowels (469G) and
install casing main joint bolts (426 & 426A). The casing
joint bolts should be tightened to the following torques:
300 ft-lb minimum for .75"-10 Ferry Cap Countr-bor
screws (Grade 8), 400 ft-lb minimum for 1.0"-8 Ferry
Cap Countr-bor screws (Grade 8). Bolt torquing pattern
is shown in Fig. 39. The number of casing bolts varies
with the size of the pump (See Fig. 23). Before tightening
bolts, be sure taper dowels are seated properly in reamed
holes.

NOTE: Torquing bolts to proper values in proper
sequence is essential in obtaining proper gasket
compression so no leakage can occur at main joint.

Fig. 28

48 3409 IOM 11/04

ADJUSTABLE WEAR RINGS

Adjustable rings are an assembly of two threaded rings
(Fig. 29). The outer, stationary ring is held in the casing by
a flange and an anti-rotation pin in the lower half main
joint. The inner, adjustable ring can be moved axially, in
either direction, by rotating it. The ring is held in position
by a stainless steel locking pin. All rings have clockwise
threads.

Adjustment

When the clearance between the impeller wear face and the
adjustable wear ring becomes excessive; i.e., approximately
.020" to .030", remove the upper half casing and pull the
locking pin.

Rotate the inner rings clockwise to restore .005" - .008"
clearance greater than shaft end float between the ring and
the impeller. Drill a new hole in the inner ring for the
locking pin. This is a blind hole — do not drill through.
Replace the locking pin and upper half casing.

Disassembly and Reassembly

Adjustable rings are removed in the same manner as
standard casing rings. They can be separated for cleaning.
Adjustable rings are installed in the pump with stationary
and the adjustable members assembled but not pinned. Turn
the adjustable member counterclockwise to provide
maximum impeller clearance and slide over shaft ends.
With the rotating element in pump, the rings can be
adjusted. Be sure that stationary member has its flange
flush against casing lower half.

(126)

SLEEVE

LOCKING

PINS

(127)

STATIONARY

RING

CASING

(100)

(127)

ADJUSTABLE

RING

IMPELLER

(101)

Fig. 29

6

Move rotating element toward outboard end as far as
bearings permit. Screw outboard end adjustable ring
toward impeller to obtain .005" - .008" axial impeller
clearance. Drill through stationary ring hole into adjustable
ring and insert locking pin. Move rotating element toward
coupling and set coupling end ring in the same manner.

3409 IOM 11/04 49

OIL LUBRICATED BEARINGS

Figs. 30 and 31 show a grease lubricated bearing housing and an
oil lubricated bearing housing, respectively. The main
difference between the two is the grease fitting and the oil ring,
respectively.

Fig. 30

The following steps describe how to change the oil for oil
lubricating bearings. Fig. 32 shows a typical oiler assembly.

Fig. 32

1. Remove the vent assembly (113A & 551F) from the top
of the bearing housing (134).

Fig. 31

To install the oil ring (114), place the oil ring in the bearing
housing directly under the pipe plug hole. Run a wire through
the pipe plug hole, around the oil ring and back through the pipe
plug hole once again. Tie the wire to a metal washer (being a
larger diameter than the hole) causing the oil ring to become
tight against the inside top of the bearing housing. Then
assemble the bearing housing over the bearing. Untie the wire
and the oil ring will drop down onto the shaft. Check the
position of the oil ring through the pipe plug hole at the top of
the bearing housing. The oil ring must be resting on the shaft
for correct operation. A screwdriver can be used to correct the
oil ring position, if required.

2. Remove the pipe plug (358V) from the bottom of the
bearing housing (134).

3. Unscrew the reservoir (251) and remove.

4. Flush the oiler (251) and bearing housing (134) with a
light grade of oil. Flush until all foreign particles have
been removed.

5. Screw the pipe plug (358V) and vent assembly (113A &
551F) back into place.

6. Fill the reservoir (251) with a good grade of filtered
mineral oil. Refer to oil lubrication instructions given
previously in this manual for type of oil.

NOTE: You must fill through Trico reservoir.

7. Place thumb over reservoir spout, invert and place
reservoir (251) on lower casting while removing thumb.
Allow reservoir to empty, filling the bearing housing
(134). Several fillings of the reservoir may be required
before the actual level is reached. When the oil level is
reached, no more oil will run out of the reservoir.

8. When reservoir stays full, screw reservoir back into lower
casting.

A periodic filling of the reservoir is required. When the oil
becomes dirty, repeat steps 1 through 8.

50 3409 IOM 11/04

VERTICAL UNITS (HALF AND FULL PEDESTAL)

UPPER CASING HALF REMOVAL

NOTE: If only the upper half casing is to be removed for
inspection of the rotating element, it will not be necessary
to remove the line shafting
or motor.

1. Do not loosen bolts (372U) holding bearing housing (134)
in casing until you are ready to remove rotating element
from casing if necessary.

! WARNING

s

Injury may result due to rotating element falling out of
lower half casing if the above procedure is not followed.
Failure to follow these instructions could result in property
damage, severe personal injury, or death.

2. Remove the larger of the two pipe plugs from the top of the
casing upper half and install an 18" to 24" solid bar
threaded at one end into the exposed tapped hole. If a
treaded bar is not available, it is permissible to use standard
pipe.

NOTE: This bar will be used to stabilize upper half
during disassembly of casing upper half. (See Fig. 33)

STABILIZER

BAR

Fig. 34

NOTE: An alignment rod is a threaded rod that screws into
bottom half of casing and is approximately 2" longer than one
half the impeller diameter. This is to prevent the top half from
falling down on impeller and also helps with alignment while
installing upper half. If not supplied with pump, they can be
made from threaded rod.

5. Sling around casing upper half ears using nylon sling,
pulling slings taught so it is not possible for slings to
slip off (See Fig. 35).

6

Fig. 33

Fig. 35

3. Disconnect the seal water lines at the stuff boxes and
remove gland bolts.

4. Remove dowel pins and all parting line bolts except for two
upper most and two lower most (See Fig. 34) Install
alignment rods (see Fig. 33) through upper half and into
tapped bottom half, one on suction side and one on
discharge side above horizontal centerline of casing.

3409 IOM 11/04 51

6. Remove two lower most bolts and then one of the two
upper most bolts.

$

Maintain downward pressure on the stabilizing rod
during this step.

7. While maintaining a downward pressure on the
stabilizer bar, unloosen the remaining upper most bolt.

CAUTION

! WARNING

s

Do not remove completely at this point. Failure to
follow these instructions could result in property
damage, severe personal injury, or death.

8. Separate the upper and lower halves by use of a pry bar
between the two halves or by the use of jacking screws if
the top half is provided with tapped holes.

9. When halves separate, slide upper half away from
lower half, maintain a downward pressure on the
stabilizing rod end furthest from the pump and slowly
remove completely the remaining upper most bolt.
Allow the top half to slide on alignment rods.

10. Balancing the upper half with the stabilizing rod, lower the
top half to the ground allowing the upper half to rotate so
that its main joint flange sets on the ground (See Fig. 36).

Fig. 36

11. Rotating element is now ready for inspection or
removal. If element is inspected and does not need to
be removed, then refer to upper half reassembly
procedures.

ROTATING ELEMENT REMOVAL

12. For these procedures it will be necessary to remove the
line shafting or motor, then remove the pump half
coupling.

Fig. 37

17. Lower rotating element to ground by sliding outboard
bearing housing away from pedestal enabling element
to be set on floor with shaft in
a horizontal position. (See Fig. 38)

Fig. 38

18. Rotating element can now be serviced following
disassembly procedure given previously in this
manual.

REASSEMBLY OF ROTATING
ELEMENT

19. Inspect main joint gasket and replace if necessary.
(Follow replacement instructions in disassembly
procedures section.)

20. Sling around the bolt in end of pump shaft.

21. On full pedestals, the lifting sling must come through hole
in top plate of pedestal (See Fig. 38).

13. Thread a long bolt, washer and nut through the hole at
the end of the shaft. (See Fig. 37)

14. Sling around eye bolt, putting slight amount of tension
on sling.

15. Remove the four bolts (372U) from each bearing
housing that are holding the bearing housing to the
casing.

16. Lightly tapping on inboard and outboard bearing
housings to spread them apart, slide rotating element
away from lower half.

22. When rotating element is off the ground and in the
vertical position, align any anti-rotation pins in the
casing rings and stuffing boxes for proper orientation
in the slots in the casing lower half.

23. Assemble rotating element in lower half casing (100).
Correctly locate casing ring pins (445A) in casing
main joint.

NOTE: Sliding inboard bearing housing toward
coupling prior to assembling rotating element in
casing will ease assembly.

52 3409 IOM 11/04

24. Bolt the outboard bearing housing (134) to lower half
casing (100) first.

$

Be sure that both bearing housing (134) are seated
properly in lower half casing (100).

25. Bolt inboard bearing housing (134) to lower half
casing (100).

NOTE: Check again to be sure bearing housings are
seated properly in lower half casing.

CAUTION

Replacing Upper Casing Half

26. Sling around lifting ears and with stabilizing rod
installed, pick casing upper half off the ground and
rotate top half so that main joint flange is vertical.
(See Fig. 36 with rotation in opposite direction shown.)

27. Move upper half casing (100) towards lower half
casing (100) using alignment rods located in lower half
casing as guides.

28. Prior to complete engagement of upper half onto lower
half, use dowel pins to guide the upper half into its
final exact position.

29. Reinstall all main joints bolts, following tightening
sequence illustrated in Fig. 39. The number of casing
bolts varies with the size of the pump. (See Fig. 23)
Torque bolts 300 ft-lb minimum for .75"-10 Ferry Cap
Countr-bor screws (Grade 8) and 400 ft-lb minimum
for 1.0"-8 Ferry Cap Countr-bor screws (Grade 8).

6

Fig. 39

NOTE: Torquing bolts to proper values in proper
sequence is essential in obtaining
proper gasket compression so no leakage
can occur at main joint.

$

If impeller was removed from shaft, double check
rotation of pump before installing upper half casing
(See Fig. 15).

30. Rotate shaft making sure it spins free. If the motor or
line shafting has been removed it will now be possible
to reinstall.

CAUTION

COMPLETE PUMP REMOVAL

Should it be necessary to remove a complete pump, it will
be necessary to remove the line shafting or motor,
disconnect the pedestal from its anchor bolts, disconnect
and remove if necessary sections of the suction and
discharge piping, and turn the entire pedestal horizontal
enabling complete pump removal from horizontal position.

3409 IOM 11/04 53

LIMITED END FLOAT COUPLINGS

For units with drivers having sleeve bearings, the coupling
halves are set to limit total shaft axial movement to less
than one-half of the motor rotor assembly end float. This is
accomplished by inserting a phenolic disc, or equivalent, of
a specified thickness between the motor and pump shaft.
(See Fig. 40)

Most 3409 pump installations use the all metal, gear type
coupling. Where limited end float gear type couplings are
used, the coupling hubs are slip-fit onto the pump and
motor shafts. After installation of the coupling covers and
hubs; with the motor set on its Magnetic Center, butt the
pump and motor shafts with the phenolic disc inserted
between them. (The pump thrust bearing limits end float
toward the pump, and the coupling covers limit end float
towards the motor.) The thrust bearing of the pump is large
enough to carry any magnetic thrust developed by the
motor when aligned properly.

Once the above instructions have been followed
completely the Alignment Procedures found in the
Installation section should then be followed.

Fig. 40

54 3409 IOM 11/04

APPENDIX I

INSTRUCTIONS FOR ORDERING PARTS

When ordering parts for 3409 pumps, be sure to furnish the following information to the Goulds Pumps stocking
distributor in your area:

l

Serial Number

l

Pump Size & Type

l

Pump Model Number

l

Pump Frame Number

l

Description of Part

l

Catalog Code

l

Quantity Required

l

Definite Billing and Shipping Instructions

l

Date Required

Refer to Appendix V for complete parts list and recommended spare parts.

Parts should be ordered as far in advance of their need as possible, since circumstances beyond the control of

Goulds Pumps may reduce existing stocks. All parts are not carried in stock. Some are made for each order. If

replacement parts required are to be made of different materials than originally specified, give exact requirements

and the reason for changing. Special care in furnishing the above information with the original order for parts will

facilitate shipment.

7

3409 IOM 11/04 55

56 3409 IOM 11/04

APPENDIX II

TOOLS

To disassemble and assemble 3409 pumps, use conventional tools.

7

3409 IOM 11/04 57

58 3409 IOM 11/04

APPENDIX III

ENGINEERING DATA

Pump Size

125# FF Std. Max. Suction Pressure (PSIG) 75 75 75 75



ASA Flanges Max. Working Pressure (PSIG) 300 300 300 300

Max. Hydrostatic Test Pressure (PSIG) 450 450 450 450

Casing Material Cast Iron Cast Iron Cast Iron Cast Iron

250# FF Max. Suction Pressure (PSIG) 200 200 200 200 200

¬

ASA Flanges Max. Working Pressure (PSIG) 400 400 400 400 400

®

Max. Hydrostatic Test Pressure (PSIG)

Casing Material Ductile Iron Ductile Iron Ductile Iron Ductile Iron Ductile Iron

Casing Wall Thickness .625 .625 .625 .625 .625

¯

STUFFING BOX DATA

Bore 5.125 5.125 5.125 5.125 5.125

Depth 4.812 4.812 4.812 4.812 4.812

Seal Cage Width .75 .75 .75 .75 .75

Packing No. Rings/Size Sq. 6/.625 6/.625 6/.625 6/.625 6/.625

Shaft Sleeve O.D. 3.875 3.875 3.875 3.875 3.875

Mechanical Seal Size (Type 8-1) 3.875 3.875 3.875 3.875 3.875

Mechanical Seal

Å

{

Size (Type 8-1B) Minor Dia. 3.875 3.875 3.875 3.875 3.875

Major Dia. 4.125 4.125 4.125 4.125 4.125

{

° 6x10-22 ° 8x12-21 ° 8x12-22M ° 8x12-22L

CASING DATA

600 600 600 600 600

(All Dimensions in Inches)

8x12-27

Not

Available

IMPELLER DESIGN DATA

Number of Vanes 66 5 6 6

Inlet Area (Sq. Inches) 59 35.7 61 80 82.4

Inlet Velocity per 100 GPM (Ft/Sec) .54 .90 .53 .40 .37

Maximum Diameter 23.0 21.8 20.5 23.0 27.0

Minimum Diameter 12.0 12.5 12.5 12.0 20.0

Maximum Sphere 1.30 1.00 1.32 1.60 1.50

WR^2 for Maximum Diameter (Lbs-Ft^2) 56 49 50 59 185

Wear Ring Clearance — Dia. BRZ Impellers .016-.019 .016-.019 .016-.019 .016-.019 .016-.019

Wear Ring Clearance — Dia. Cl and SS Impellers .025-.028 .025-.028 .025-.028 .025-.028 .025-.028

SHAFT AND BEARING DATA

At Coupling 3.125 3.125 3.125 3.125 3.125

Thru Impeller and Sleeves 3.311 3.311 3.311 3.311 3.311

Shaft Span Bearing to Bearing Centerline 35.800 35.800 35.800 35.800 40.500

Ball Bearing Inboard 6316 6316 6316 6316 6316

Outboard 21316 21316 21316 21316 21316

Frame Group SS S S M

¬ With 250# FF flanges refer to pump as H6x10-22.

 Flange dimensions are in accordance with ANSI A21.10,

AWWA C110 and ANSI B16.1 Class125.

¯ The hydrostatic test will be in accordance with the latest

edition of the Hydraulic Institute Standards, test will be
maintained for a minimum of 10 minutes.

° 6x10-22, 8x12-21, and 8x12-22M/L are standard with

® Flange dimensions are in accordance with ANSI B16.1 Class

250 except flanges are flat faced.

125# FF suction and 250# FF discharge flanges.

± Balanced mechanical seals have a major and a minor

diameter as listed.

7

3409 IOM 11/04 59

ENGINEERING DATA

Pump Size

CASING DATA

125# FF Std. Max. Suction Pressure (PSIG) 75 75 75 75 75 75



ASA Flanges Max. Working Pressure (PSIG) 175 175 175 175 175 175

Max. Hydrostatic Test Pressure (PSIG) 262 262 262 262 262 262

Casing Material Cast Iron Cast Iron Cast Iron Cast Iron Cast Iron Cast

250# FF Max. Suction Pressure (PSIG) 200 200 200 200 200 200

¬

ASA Flanges Max. Working Pressure (PSIG) 300 300 300 300 300 300

®

Max. Hydrostatic Test Pressure (PSIG)

Casing Material Ductile Iron Ductile Iron Ductile Iron Ductile Iron Ductile Iron Ductile Iron

Casing Wall Thickness .625 .625 .625 .625 .625 .625

¯

STUFFING BOX DATA

Bore 5.125 5.125 5.125 5.125 5.875 5.875

Depth 4.812 4.812 4.812 4.812 4.812 4.812

Seal Cage Width .75 .75 .75 .75 .75 .75

Packing No. Rings/Size Sq. 6/.625 6/.625 6/.625 6/.625 6/.625 6/.625

Shaft Sleeve O.D. 3.875 3.875 3.875 3.875 4.625 4.625

Mechanical Seal Size (Type 8-1) 3.875 3.875 3.875 3.875 4.625 4.625

Mechanical Seal

Å

{

Size (Type 8-1B) Minor Dia. 3.875 3.875 3.875 3.875 4.500 4.500

Major Dia. 4.125 4.125 4.125 4.125 4.750 4.750

{

10x14-20S 10x14-20L 12x16-23 14x16-17 14x18-23 14x18-28

(All Dimensions in Inches)

450 450 450 450 450 450

(All Dimensions in Inches)

IMPELLER DESIGN DATA

Number of Vanes 66 6 6 66

Inlet Area (Sq. Inches) 112 128 150 171 212 196

Inlet Velocity per 100 GPM (Ft/Sec) .29 .25 .21 .19 .15 .16

Maximum Diameter 19.8 19.8 23.0 17.5 23.0 27.9

Minimum Diameter 9.4 14.0 13.0 12.5 14.0 14.0

Maximum Sphere 1.63 1.56 1.63 1.20 2.10 1.30

WR^2 for Maximum Diameter (Lbs-Ft^2) 47 52 109 46 120 254

Wear Ring Clearance — Dia. BRZ Impellers .016-.019 .016-.019 .016-.019 .016-.019 .016-.019 .016-.019

Wear Ring Clearance — Dia. Cl and SS Impellers .025-.028 .025-.028 .025-.028 .025-.028 .025-.028 .025-.028

SHAFT AND BEARING DATA

At Coupling 3.125 3.125 3.125 3.125 3.125 3.125

Thru Impeller and Sleeves 3.311 3.311 3.311 3.311 4.061 4.061

Shaft Span Bearing to Bearing Centerline 40.500 40.500 40.500 40.500 41.375 41.375

Ball Bearing Inboard 6316 6316 6316 6316 6316 6316

Outboard 21316 21316 21316 21316 21316 21316

Frame Group MM M M L L

¬ With 250# FF flanges refer to pump as H6x10-22.

 Flange dimensions are in accordance with ANSI A21.10,

AWWA C110 and ANSI B16.1 Class125.

¯ The hydrostatic test will be in accordance with the latest

edition of the Hydraulic Institute Standards, test will be
maintained for a minimum of 10 minutes.

(All Dimensions in Inches)

(All Dimensions in Inches)

° 6x10-22, 8x12-21, and 8x12-22M/L are standard with 125# FF

® Flange dimensions are in accordance with ANSI B16.1 Class

250 except flanges are flat faced.

suction and 250# FF discharge flanges.

± Balanced mechanical seals have a major and a minor

diameter as listed.

60 3409 IOM 11/04

APPENDIX IV

MODEL 3409 CROSS SECTIONAL

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3409 IOM 11/04 61

MODEL 3409 CROSS SECTIONAL

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62 3409 IOM 11/04

APPENDIX V

REPLACEMENT PARTS LIST

ITEM NO.

100
100 CASING, LOWER HALF 1
101 IMPELLER 1
102 PIPING 2
105 LANTERN RING 2

106* PACKING, STUFFING BOX 1 SET

107
109 END COVER, IB THR. BRG 1
111 CAP. BRG. HSG. END 1

113A BREATHER 2

114 RING, OIL 2
119 END COVER, IB CPLG. BRG. 1
122 SHAFT 1

124 NUT, SLEEVE 2
126* SLEEVE, SHAFT 2
127* RING, CASING WEAR 2

134 HOUSING, BEARING 2

136 LOCKNUT, BEARING 1

142 RING, IMPELLER WEAR 2

168 BEARING, RADIAL BALL 1

178 KEY, IMPELLER 1

190E NIPPLE, OILER PIPE 2

193 FITTING, STRAIGHT DRIVE GREASE 2

222B SCREW, SLEEVE NUT SET 2

250 GLAND, MECHANICAL SEAL 2

251 OILER 2

276 RING, THR. BRG. RETAINING 1

319H VENT, AIR 2

332A/333A ISOLATOR, BEARING 3

351D* GASKET, CASING PARTING DISCH. 1
351S* GASKET, CASING PARTING SUCT 1

353B SCREW, GLAND HEX CAP 4/8

354 WASHER, GLAND 4/8

358U PLUG, FRAME OILFILL PIPE 2
358V PLUG, PIPE FRAME 4

360 GASKET, END COVER 2

371C SCREW, HEX (BRG. HSG./END COVER) 4
372U SCREW, HEX CAP (HSG./CASING) 8

382 LOCKWASHER, BEARING 1
383* SEAL, MECHANICAL 2

400 KEY, COUPLING 1

401 KEY, SLEEVE 2

408F PLUG, CASING PIPE 9
408G PLUG, CASING PIPE 5

410 BEARING, THRUST BALL 1

412G* O-RING, MECHANICAL SEAL 2

418 BOLT, JACK 2

424A PIN, NAMEPLATE 10

426 SCREW, PARTING HEX CAP Size Dependent

426A SCREW, PARTING HEX CAP Size Dependent

428 GASKET, SLEEVE 2

433 NAMEPLATE, FRAME 1

433A NAMEPLATE, CASING 1
433B NAMEPLATE, LOGO CASING 2
445A PIN, ANTIROTATION 2
469G PIN, TAPER WITH HEX NUT 2
496L O-RING, END CAP 1

497* O-RING, SLEEVE NUT 2

535 WASHER, BEARING (OUTBOARD) 1

551F BUSHING, REDUCER 2

CASING, UPPER HALF

GLAND, STUFFING BOX

PART NAME

* Recommended Spare Parts

3409 IOM 11/04 63

QTY.

1

2

7

64 3409 IOM 11/04

APPENDIX VI

USEFUL FORMULAS

7

3409 IOM 11/04 65

66 3409 IOM 11/04

3409 IOM 11/04 67

FIELD TEST REPORT

APPENDIX VII

Field Test Report

Date ________________

Pump Size _______________________ Pump Type _______________________ RATING: GPM _______________ Head ____________ RPM _____________

Pump Serial Number _______________ Impeller Diameter (in.) ______________ Suction gauge pipe size ___________________________ inches

Manufacturer’s Pump Curve Number ___________________________________ Discharge gauge connection pipe size _________________ inches

Discharge gauge elevation corr. ______________________ feet

MOTOR:** Rated HP ____________ Volts _______________ S.F. ___________ Barometric pressure ____________ inches Hg x 1.13 = __________ feet water

F.L. Amps ____________ F.L. Eff _____________ P.F. ___________ Liquid pumped ________________ S.G. __________

Phase _______________ Liquid temperature _____________ °F

Liquid vapor pressure ___________ psi x 2.31 = __________feet water

Affinity Law

Corrections

TDH1GPM1BHP

1

1

P

O

I

Discharge

Pressure

Gauge

Suction

Pressure

Gauge
N
T

(PSI.) (ft.) (PSI.) ( ft.) Disc. Suct.

Velocity

Head
(feet)

Total

Dynamic

Head

(TDH

FLOW

RPM

2

ing

Convert to
GPM

Read-

2)

Moto

2

Volts

r

Motor Amps

Leg

Leg2Leg

1

Avg.

Amps

3

Pump
BHP

(calc’d)

Pump

Eff.

2

(calc’d)

RPM

1

2

3

4

5

6

7

8

9

10

Calc’d

N
P
S
H
A

N
P
S
H
R*

* NPSHR taken from manufacturer’s pricebook curve. Type of flow measurement device: ____________________________________
** Motor information taken off motor nameplate.

See sheet 2 of 2 for useful formulas. Readings taken by: ________________________________________________

Comments: _______________________________________________________________

_______________________________________________________________

7

HOW TO ORDER

When ordering parts call

1-800-446-8537, or

your local Goulds Pumps Representative

EMERGENCY SERVICE

Emergency Parts Service is available

24 hours / day, 365 days / year …

Call 1-800-446-8537

Visit our website at www.gouldspumps.com

Form No. I3409 11/04

© 2004 Goulds Pumps, Incorporated

a subsidiary of ITT Industries, Inc.