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Fairmont 42190
Specifications And Parts List
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Greenlee Fairmont H4660B, Fairmont 42190 Service Manual

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SERVICE MANUAL
H4660B/42190
Submersible Pump
999 1468.9 REV 8 © 2005 Greenlee Textron Inc. 11/05
Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
Table of Contents
Safety .............................................................................2
Purpose .......................................................................... 2
Other Publications .......................................................... 2
Important Safety Information ....................................... 3-4
Disassembly ................................................................... 5
Inspection ....................................................................... 6
Assembly.....................................................................6-8
Exploded Views and Parts List..................................9-12
Accessories .................................................................. 13
Safety
Safety is essential in the use and maintenance of Fairmont tools and equipment. This instruction manual and any decals on the tool provide information for avoiding hazards and unsafe practices related to the use of this tool. Observe all of the safety information provided.
Purpose
This manual is intended to familiarize all personnel with the safe service procedures for the H4660B/42190, serial code FLM Submersible Pump. Keep this manual available to all personnel.
Replacement manuals are available upon request at no charge.
Loctite® is a registered trademark of Loctite Corporation.
Other Publications
Operation Manual: Publication 99928159 Specifications and Parts Manual:
H4660B/42190: Publication 99930412
SAE Standard J1273 (Hose and Hose Assemblies):
Publication 99930323
Greenlee / A Textron Company 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
KEEP THIS MANUAL
IMPORTANT SAFETY INFORMATION
SAFETY ALERT SYMBOL
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for prevent­ing or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result in severe injury or death.
Do not operate the pump if the impeller blades are exposed. After assembly, install the inlet screen before operating the pump.
Failure to observe this warning could result in severe injury or death.
Do not inspect, adjust, or clean tool when it is connected to a power source. Accidental startup can result in serious injury.
Hazards which, if not avoided, COULD result in severe injury or death.
Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage.
Before operating this tool, see the safety information and operating instructions in the Operation Manual.
Skin injection hazard: Oil under pressure easily punctures
skin causing serious injury, gan­grene or death. If you are injured by escaping oil, seek medical attention immediately.
• Do not use fingers or hands to check for leaks.
• Do not hold hose or couplers while operating the power source.
• Depressurize the hydraulic system before servicing.
Greenlee / A Textron Company 3 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
IMPORTANT SAFETY INFORMATION
Wear eye protection when operating or servicing this tool.
Failure to wear eye protection could result in serious eye injury from flying debris or hydraulic oil.
Do not exceed the maximum hydraulic flow, pressure relief or back pressure listed in the Specifications and Parts manual.
Failure to observe this warning could result in severe injury or death.
Do not disconnect tool, hoses, or fittings while the power source is running or if the hydraulic fluid is hot. Hot hydraulic fluid can cause serious burns.
Hydraulic oil can cause skin irritation.
• Handle the tool and hoses with care to prevent skin contact with hydraulic oil.
• In case of accidental skin contact with hydraulic oil, wash the affected area immediately to remove the oil.
Failure to observe these precautions may result in injury.
Do not reverse hydraulic flow. Operation with hy­draulic flow reversed can cause tool malfunction. Connect the supply (pressure) hose and return (tank) hose to the proper tool ports.
Procedure for disconnecting hydraulic hoses, fittings or components:
1. Move the flow lever on the hydraulic power
source to the OFF position.
2. Stop the power source.
3. Follow the sequence under Disconnecting Hoses
to prevent pressure buildup. In case some pressure has built up, loosen hoses, fittings or components slowly.
Greenlee / A Textron Company 4 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Note: Keep decals clean and legible. Replace decals when necessary—see the decals listed in the Parts and Specifications manual.
Disassembly
Complete disassembly of the tool is not recommended. If a complete overhaul is necessary, return the tool to your nearest authorized Fairmont distributor or to Fairmont.
The disassembly procedure is divided into sections of the tool. Disassemble only the section(s) necessary to complete the repair.
Disassemble the tool on a flat, clean surface. Take care not to lose or damage any parts that may fall free during disassembly.
Inlet Screen (Strainer)
Remove six hex head cap screws (27), lock washers (28) and flat washers (29). Remove sub base (26), inlet screen (strainer) (24) and six bushings (25). Remove inlet (23) from housing (1).
Housing
Note: Mating surfaces of the housing (1) and impeller (13) are critical. Use every caution to prevent damage to these parts.
Remove six hex nuts (16), lock washers (15) and flat washers (30). Remove housing (1) and gasket shims (3, 4) from motor adapter (5).
Impeller
Lock impeller (13) in place by placing an appropriate diameter hardened rod, approximately 4.3 mm (.171"), into one of the small holes in impeller, and mating pin with hole in motor adapter (5). If no rod is available, place a screwdriver between the blades of impeller. Remove hex jam nut (14). Remove impeller (13), Woodruff key (11) and shim (12) from shaft (7).
Motor
1. Scribe a line across body (15) and rear cover (12)
to align parts correctly during assembly. If body or rear cover are to be replaced as new components during assembly, scribe a line on new part in same location as the component it replaced.
2. Remove Woodruff key (10) from drive shaft (14).
3. Secure motor in a vise, using light clamping
pressure, with shaft end down. Remove four hex head cap screws (1) and flat washers (2).
4. Separate rear cover (12) from body (15) by support-
ing motor, shaft end up, on mounting flanges and pressing on drive shaft (14) end in an arbor press, or by tapping on drive shaft end with a plastic head mallet. Do not use a metal hammer.
Note: Use one hand to support rear cover from underneath, since rear cover and internal parts will drop suddenly when dowels are disengaged.
5. Remove dowel pins (7) from rear cover or body.
If square cut ring (3) and thrust plate (4) remain in body, remove them. Do not remove pipe plug (17) from rear cover unless necessary.
6. Remove idler shaft with gear (13), drive shaft with
gear (14), and wear plate (5) with pressure loading seal (6) from body. Remove pressure loading seal from wear plate.
7. Remove retaining ring (8) and packing gland (9)
from body.
Note: Do not damage packing gland bore of body. This could result in leakage.
Motor, Motor Adapter and Handle
1. Remove two hex head cap screws (18) and lock washers (15). Remove motor assembly (17) from motor adapter (5). If necessary, remove handle (19) from motor adapter (5) by removing two hex head cap screws (20) and lock washers (21).
2. Remove internal retaining ring (10) from motor adapter (5). Using a plastic head mallet, tap on threaded end of shaft (7) to drive out shaft (7) and bearings (8). Remove external retaining ring (9) from shaft (7) and pull off two bearings (8).
Greenlee / A Textron Company 5 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
AssemblyInspection
Clean all parts with solvent and dry them thoroughly. Inspect each component as described in this section. Replace any component that shows wear or damage.
1. Bearings: Insert shaft into bearings. Spin shaft. If shaft does not spin smoothly, replace the entire assembly with the bearings already pressed in.
2. Cover and Body: Inspect mating surfaces, gear cavities, oil passageways, etc. for grooves or nicks. If any component shows wear or damage, replace the entire assembly with the bearings already pressed in.
3. Wear Plate and Thrust Plate: Inspect surfaces for grooves or nicks. An even wear pattern is accept­able. Replace any component that shows excessive wear or damage.
4. Thrust rings: Replace any thrust ring that is out-of-round.
5. Inspect all other disassembled components for cracks, grooves, or nicks.
Refer to the Exploded View(s) and Parts List for correct orientation and placement of parts.
Replace any O-rings, V-rings, seals, and gaskets on parts that have been disassembled. Apply hydraulic fluid or O-ring lubricant to all O-rings and all metal surfaces which they must slide over. When installing an O-ring which must slide over sharp surfaces, use a rolling motion and be careful not to damage the O-ring.
Wherever the assembly results in metal-to-metal contact, coat the surfaces with hydraulic fluid or O-ring lubricant.
Motor
1. Install packing gland (9) into packing gland bore in body (15). Secure packing gland with retaining ring (8), with its square outer edge facing outwards.
2. Install pressure loading seal (6), with its smooth, flat surface facing outward, in grooves in wear plate (5).
Note: Pressure loading seal surface must protrude from wear plate surface no less than 12.7 mm (.005"). Do not install seal flush or beneath surface of wear plate (5).
3. Install wear plate (5) with pressure loading seal (6) in body (15), with pressure loading seal surface facing towards the gear bores in body.
4. Lubricate needle bearings in body (15) and face of wear plate (5) with SAE 10W oil. Install drive shaft with gear (14) in body. Install idler shaft with gear (13) in body, with long journal towards front of motor. Mesh the two gears together.
5. Lubricate rear gear faces and journals with SAE 10W oil. Install thrust plate (4), with its bronze thrust surface against gear faces.
6. Install dowels (7) in body (15).
7. Apply a small amount of clean grease to groove in rear cover (12). Install a new square cut ring (3) in groove.
8. Lubricate rear cover bearings with SAE 10W oil. Maintain body in a vertical position with gear bores facing upward. Place rear cover (12) on body (15), aligning the scribe marks on rear cover and body.
Note: The body must be maintained in a vertical position, with gear bores facing upward during rear cover installation to prevent shifting of the thrust plate. Any shift of the thrust plate will result in pinching between the body and rear cover when hex head cap screws are installed.
9. Position motor in an arbor press, with shaft end down, and press on rear cover (12), or install all hex head cap screws (1) and washers (2) and pull down rear cover evenly in small increments.
10. When rear cover is pulled down firmly against body, torque hex head cap screws to 52.8 Nm (39 ft-lb).
Greenlee / A Textron Company 6 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Assembly (cont’d)
Motor (cont’d) Impeller Clearance
11. If pipe plug (17) was removed, reinstall plug in rear cover and torque to 41 to 54 Nm (30 to 40 ft-lb).
12. Install Woodruff key (10) in drive shaft (14).
13.
Turn drive shaft. Drive shaft must turn without binding.
Motor Test Procedure
Note: The test stand should contain hydraulic fluid maintained at a temperature of 46 - 52° C (115 - 125° F). See Recommended Hydraulic Fluids in Specifications and Parts.
1. Plug return (T) port of motor.
2. Connect pressure line of hydraulic power source to pressure port (P) of motor.
3. Start hydraulic power source and supply 19 l/min @
137.9 bar (5 gpm @ 2000 psi) to motor. Motor must not have any leakage.
Motor Break-In Procedure
Note: Motor break-in is required only if any worn internal components were replaced with new components.
Note: Before connecting hoses, see Specifications and Parts List for power source specifications. Install a 100-mesh screen at motor inlet port. Install a 0 - 35 bar (0 - 500 psi) pressure gauge in the return line.
1. Connect pressure and return lines of hydraulic power source to appropriate pressure (P) and return (T) ports of motor.
2. Start hydraulic power source and supply 19 l/min @
137.9 bar (5 gpm @ 2000 psi) to motor. Run motor for three minutes. Motor must not have any leakage.
Motor, Motor Adapter and Handle
1. Install two bearings (8) on shaft (7) and secure using external retaining ring (9). Slide shaft with bearings into motor adapter (5) and secure using internal retaining ring (10).
Note: Pumps manufactured since 1993 have motor adapter (5) that requires an O-ring (32).
• If your adapter has an O-ring groove, install the
O-ring (32).
• If your adapter does not have an O-ring groove,
clean mating surfaces of motor and housing with Loctite® 755-59 Safety Solvent, or equivalent. Coat one surface evenly with silicon sealer and allow ten minutes to dry before assembling.
2. Install complete motor assembly (17) in motor adapter (5). Make sure Woodruff key in motor drive shaft slides into slot of shaft (7) in motor adapter. Secure motor to motor adapter (5) with two hex head cap screws (18) and lock washers (15). If handle (19) was removed, install on motor adapter (5) and secure with two hex head cap screws (20) and lock washers (21).
1. Slide shim (12) onto end of shaft (7). Install Woodruff key (11) in keyway of shaft (7). Slide impeller (13) onto shaft, guiding keyway in impeller over the Woodruff key in shaft.
2. Lock impeller (13) in place by placing an appropriate diameter hardened rod, approximately 4 mm (.171"), in one of the small holes in impeller and mating the rod with hole in motor adapter (5). If no rod is available, place a screwdriver between blades of impeller. Secure impeller to shaft with jam nut (14).
3. Check clearance between impeller (13) and motor adapter (5). The clearance between these compo­nents should be 0.5 - 1 mm (.020 - .044"). Add or remove shim(s) (12) between impeller (13) and shaft (7) as needed to achieve proper clearance.
4. To set impeller/housing clearance, install six (brown) gasket shims (4) on motor adapter (5), and set motor and motor adapter subassembly on housing. Begin removing gasket shims (4) until there is interference between the impeller (13) and housing (1). When an interference is achieved, add one gasket shim, either the (blue) gasket shim (3) or a (brown) gasket shim (4), whichever one achieves a minimum clearance without impeller/housing interference.
5. After setting impeller clearance, secure motor adapter (5) to housing (1) by installing six hex nuts (16), lock washers (15) and flat washers (30) on studs protruding up from mounting holes in motor adapter (5).
Inlet Screen (Strainer)
1. Install six hex head cap screws (27), with lock washers (28) and flat washers (29) into sub base (26). Position base so the threaded end of hex head cap screws are pointing upwards.
2. Slide bushings (25) over hex head cap screws (27). Snap inlet screen (strainer) (24) into groove in base (26). Slide inlet (23) over hex head cap screws (27), and snap groove in inlet (23) securely onto inlet screen (strainer) (24).
3. Install strainer assembly on bottom of housing (1) using six hex head cap screw (27). Tighten cap screws securely.
Greenlee / A Textron Company 7 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Exploded View
H4660B/42190 Submersible Pump
33
12
37
36
16
18
15
34
17
10
32
19
20
21
35 37
7
8
9
6
11
22
13
14
1
23
15
30
24
5
3
4
25
26
29
28
27
Greenlee / A Textron Company 8 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Parts List
H4660B/42190 Submersible Pump
Key 78-3310- Part No. Description Qty
UPC No.
42190 137432 H4660B Submersible pump
1 41071 137459 Housing (includes next item) ............................................................. 1
F023663 Stud, 3/8–16 x 1.50" stainless steel .................................................. 6
3* 40631 130676 Gasket shim, .005" (blue) .................................................................. 1
4* 40473 123444 Gasket shim, .010" (brown)............................................................... 6
5 40378 114805 Motor adapter .................................................................................... 1
6* 41434 F013641 O-ring, .937 x 1.187 x .125"–80 D ..................................................... 1
7 41146 139533 Shaft .................................................................................................. 1
8 41717 F018706 Bearing, ball, .875 x 1.875 x .500" D................................................. 2
9 41298 F009117 Retaining ring, external, .875" ........................................................... 1
10 41342 F011056 Retaining ring, internal, 1.875" .......................................................... 1
11 43405 137155 Key .................................................................................................... 1
12 40391 116364 Washer, flat, .631 x .868 x .010" ....................................................... 2
13 41147 139534 Impeller ............................................................................................. 1
14 42073 F023662 Nut, hex, 5/8"–18, stainless steel ...................................................... 1
15 43950 F023661 Washer, lock, .382 x .683 x .094" stainless steel .............................. 8
16 43951 F023656 Nut, hex, 3/8"–16 stainless steel ....................................................... 6
17 90501217 Gear motor ........................................................................................ 1
18 F023715 Screw, cap, 3/8–16 x 1.00" socket head ........................................... 2
19 40384 114814 Handle ............................................................................................... 1
20 43948 F024748 Screw, cap, 5/16–18 x .625" socket head ......................................... 2
21 43949 F023657 Washer, lock .328 x .586 x .078" stainless steel ............................... 2
22 44089 F009188 45° Elbow, 1/8 M NPT x 1/8 F NPT .................................................. 1
23 41069 137415 Inlet ................................................................................................... 1
24 43067 137416 Inlet screen (strainer) ........................................................................ 1
25 43079 L060311 Bushing ............................................................................................. 6
26 43938 137417 Sub base ........................................................................................... 1
27 42800 L083097 Screw, cap, 1/4–20 x 3.50" hex head ............................................... 6
28 42813 L084018 Washer, lock 1/4" (.271 x .489 x .062") ............................................. 6
29 42814 L084019 Washer, flat, 1/4" (.265 x .510 x .065") ............................................. 6
30 43999 F014349 Washer, flat, .406 x .812 x .065" stainless steel ............................... 6
31 41547 F015482K1 Decal, Fairmont ................................................................................. 1
32 42094 F024580 O-ring, 3.25 x 3.375 x .062"–70D...................................................... 1
33 42105 F024775 Coupling, 2-1/2" M NPT .................................................................... 1
34 F014349 Washer, flat, .375", stainless steel .................................................... 2
35 50141 90501411 Adapter, 1-1/16 male SAE x 1/2 female NPT .................................... 1
36 F014243 Adapter, 7/8-14 male SAE x 1/2 female NPT.................................... 1
37 43186 F011339 90° Elbow, 1/2 male NPT x 1/2 male NPT ........................................ 2
Repair Kits
* 40795 132659 Packing kit
Greenlee / A Textron Company 9 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
(includes items marked with an asterisk)
Accessories
Discharge Hose Assembly
3421
UPC No.
Key 78-3310- Part No. Description Qty
41219 156339 Hose assembly, heavy-duty discharge
1 F024776 Coupling, cam lock, 2.25" ID x 6.00"
for discharge hose ..................................... 1
2 F011057 Clamp, hose .............................................. 4
3 F024774 Hose, discharge 25 ft., 2.5" ID ................... 1
4 55209 90552091 Coupling, male ..........................................1
55213 90552130 Hose assembly, contractor discharge
1 F024776 Coupling, female .......................................1
2 F011057 Clamp, hose .............................................. 4
4 55209 90552091 Coupling, male .......................................... 1
Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
USA 800-435-0786 Fax: 800-451-2632 815-397-7070 Fax: 815-397-1865 Canada 800-435-0786 Fax: 800-524-2853 International +1-815-397-7070 Fax: +1-815-397-9247
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company
www.greenlee.com
•
Greenlee Textron Inc. is a subsidiary of Textron Inc.
Printed in USA
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