Grundfos 72, 74, 78 Service Instructions Manual

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Page 1

GRUNDFOS INSTRUCTIONS

S pumps, range 72 - 74 - 78

DIN 50/60 Hz

Service instructions

Page 2

English (GB) Service instructions

Caution

Note

English (GB)

Original service instructions.

CONTENTS

1. Symbols used in this document

2. Servicing S pumps with explosion-proof motors

3. Safety

4. Identification

4.1 Nameplate

4.2 Type key

5. Handling the pump

5.1 Lifting the pump

5.2 Lifting points

5.3 Raising pump to upright position

6. Torques, lubricants and special liquids

6.1 Common torques

6.2 Special torques and lubricants

6.3 Quantities of grease in bearings

6.4 Special liquids

7. Service tools

7.1 Standard tools

7.2 Special tools

7.3 Tightness test tools

7.4 Lifting tools

8. Service

8.1 General information

8.2 Pump cleaning and visual inspection

8.3 Annual maintenance

8.4 Oil check and oil change

8.5 Inspection and adjustment of impeller clearance

9. Dismantling and assembly instructions

9.1 Checking and replacing the cable

9.2 Replacing the terminal board

9.3 Replacing the protection sensors

9.4 Dismantling range 72

9.5 Assembling range 72

9.6 Dismantling range 74

9.7 Assembling range 74

9.8 Dismantling range 78

9.9 Assembling range 78

10. Tightness tests

10.1 Tightness test of stator (submerged)

10.2 Tightness test of terminal box (cable side, submerged)

11. Drawings

11.1 Range 72

11.2 Range 74

11.3 Range 78

11.4 Position numbers and material specification

11.5 Sensor positions

11.6 Electrical connections

Page

10 10 10 11 12

13 14 17 19 21 23 25 29 30

32 32

33 42 48 56 58 60

1. Symbols used in this document

Warnin g If these safety instructions are not observed,

2 3 3 3

3 4

6 6 6

7 7 7 7

8 9 9 9

it may result in personal injury.

Warnin g These instructions must be observed for

explosion-proof pumps. It is advisable also to follow these instructions for standard pumps.

Warnin g If these instructions are not observed, it may lead

to electric shock with consequent risk of serious personal injury or death.

Warnin g The surface of the product may be so hot that

it may cause burns or personal injury.

Warnin g The sound pressure level is so high that hearing

protection must be used.

If these safety instructions are not observed, it may result in malfunction or damage to the equipment.

Notes or instructions that make the job easier and ensure safe operation.

Page 3

2. Servicing S pumps with explosion-proof

Note

motors

S pumps, range 72 to 78 have the following explosion protection classification:

Direct drive, 50 or 60 Hz CE 1180 II2 G Ex bc d IIB T4

74, 78

Service work on Ex pumps must be carried out by Grundfos or a workshop authorised by Grundfos. Violation of this requirement will invalidate the Ex classification of the pump.

Overhauled and repaired explosion-proof pumps are provided with a repair plate giving the following information:

• the repair symbol R

• name of registered trade mark of the repairing workshop

• workshop reference number relating to the repair

• date of overhaul or repair. In case of subsequent repairs, the existing repair plate should be

replaced by a new, updated repair plate and earlier markings must be recorded.

The repairing workshop must keep records of performed overhauls and repairs together with records of all previous overhauls, repairs and possible modifications. Copies of the repairing workshop’s detailed records should be filed by the owner or operator together with the original type certificate of the explosion-proof motor in question.

Frequency converter drive

Direct drive, 50 or 60 Hz Only on request Frequency converter

drive

CE 1180 II2 G Ex bc d IIB T3

Only on request

3. Safety

Warning Pump installation in pits must be carried out by

specially trained persons. Work in or near pits must be carried out

according to local regulations.

For safety reasons, all work in pits must be supervised by a person outside the pump pit.

Pits for submersible sewage and wastewater pumps contain sewage and wastewater with toxic and/or disease-causing substances. Therefore, all persons involved must wear appropriate personal protective equipment and clothing, and all work on and near the pump must be carried out under strict observance of the hygienic regulations in force.

Warning Before attempting to lift the pump, make sure the

rated capacity of the lifting equipment (lifting chain etc.) is adequate for the lifting work.

The rated capacity of the lifting equipment is stated on the equipment nameplate. The weight of the pump is stated on the pump nameplate.

4. Identification

4.1 Nameplate

English (GB)

TM05 8220 2113

Fig. 1 Pump nameplate

All pumps can be identified by means of the nameplate on the motor top cover, see fig. 1.

Pos. Description

1 Type designation 2 Product number 3 Serial number 4 Maximum head (m) 5 Number of phases 6 Voltage, delta connection 7 Voltage, star connection 8 Rated power input (kW)

9 Power factor (Cos φ) 10 Production code (YYWW) 11 Model 12 Maximum liquid temperature 13 Maximum flow rate (l/s) 14 Enclosure class according to IEC 60529 15 Frequency (Hz) 16 Rated speed 17 Current, delta connection 18 Current, star connection 19 Rated power output P2 20 Insulation class 21 Weight

If a pump has been used for a liquid which is injurious to health or toxic, the pump will be classified as contaminated.

If Grundfos is requested to service the pump, Grundfos must be contacted with details about the pumped liquid, etc., before the pump is returned for service. Otherwise Grundfos can refuse to accept the pump.

Possible costs of returning the pump are paid by the customer. However, any application for service (no matter to whom it may

be made) must include details about the pumped liquid if the pump has been used for liquids which are injurious to health or toxic.

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4.2 Type key

English (GB)

All S pumps, range 72, 74 and 78, described in this product guide are identified by the type designation stated in the confirmation of order and other documentation supplied with the pump.

Please note that the pump type described in this type key is not necessarily available in all variants.

Code Example S 2 .90 .250 .2250 .4 .72 S .C .496 .G .N .D .5 13 .Z

Pump type:

Grundfos sewage and wastewater pump

Multi-channel impeller pump installed in a column pipe

Impeller type:

Two-channel

Three-channel

Four-channel

Pump passage:

Maximum solids size [mm]

Pump discharge, S type:

250

Nominal diameter of pump discharge port [mm]

Pump discharge, ST-type:

[ ]

Nominal diameter of column pipe [mm]

Output power, P2:

P2 = Code number from type designation/10 [kW]

Number of poles:

4-pole motor

6-pole motor

8-pole motor

10-pole motor

12-pole motor

14-pole motor

Pump range:

Pressure version:

Super-high

High

Medium

Low

Extra-low

Super low

Installation type:

Submerged installation without cooling jacket

Submerged installation with cooling jacket

Dry installation with cooling jacket

Dry horizontal installation with cooling jacket

Impeller diameter (average):

[mm]

Material code for impeller, pump housing and stator housing:

Cast iron impeller, pump housing and stator housing

Cast iron pump with stainless steel impeller

Pump version:

Non-explosion-proof pump

Pump with explosion-proof motor

Sensor version:

S pump with built-in SM 113 module. PTC sensors are connected directly to IO 113 or other PTC relay.

S pump without built-in SM 113 module

Frequency:

50 Hz

60 Hz

Voltage and connection:

50 Hz 60 Hz 3 x 400 / 690 V Y/D 3 x 575 / (996) V Y/D

3 x 415 / 719 V Y/D

3 x 380-400 / 660-690 V Y/D

18 58 1G

3 x 380 / 660 V Y/D 3 x 380 / 660 V Y/D

3 x 460 / (797) V Y/D

3 x 400-415 / 690-719 V Y/D

3 x 380-415 / 660-719 V Y/D

Z Custom-built products

Page 5

Type key used for frame size 74 and 78 until 2010. May still be used for spare pumps manufactured later.

Code Example S 2 X 250 4 H 2 5 11 Z

Pump type:

Grundfos (or Sarlin) wastewater pump/sewage pump

Impeller type:

Two-channel

Three-channel

Four-channel

Axial Propeller

Multi-channel, small pump passage

Pump version:

Standard pump

[ ]

In conformity with the ATEX directive

Power:

100

Motor power in kW

Number of poles:

2-pole motor

4-pole motor

6-pole motor

8-pole motor

10-pole motor

12-pole motor

14-pole motor

Pump generation:

First generation

[ ]

Second generation

Third generation

Pressure version:

No classification

[ ]

Super high

High

Medium

Low

Super extra low

Installation type:

Submerged installation without cooling jacket

Submerged installation with cooling jacket

Dry installation with cooling jacket

Submerged installation, portable. Pump without cooling jacket.

Submerged installation, portable. Pump with cooling jacket.

Dry horizontal installation with base stand and bracket. Pump with cooling jacket

Submerged column installation

Interchangeability:

No letter indicates full interchangeability of parts and use of the same spare parts catalogue.

[ ]

The letters (A, B, C...) indicate interchangeability of parts between otherwise identical pumps.

A,B,C

Number of phases:

Single-phase

Three-phase

[ ]

Frequency:

50 Hz

60 Hz

Voltage and starting method:

50 Hz 60 Hz 660-690 V Y

288-500 V Y/D

400-690 V Y/D 460-(796) V Y/D

220-380 V Y/D

415-(719) V Y/D

500-(865) V Y/D

380-660 V Y/D

Special equipment:

Flanges sized according to ANSI specifications

Non-standard parts:

Special diameter in impeller

Special length of cable

Combination of C and D or other special part

Material code for impeller, pump and stator housing:

Stainless steel impeller, pump housing and stator housing, AISI 316 (DIN W.-Nr. 1.4408)

Stainless steel impeller and pump housing, AISI 316 (DIN W.-Nr. 1.4408) Stainless steel impeller, AISI 316 (DIN W.-Nr. 1.4408)

English (GB)

Page 6

5. Handling the pump

English (GB)

S pumps, range 78 weigh up to 7800 kg without accessories. It is therefore very important to use the right lifting equipment.

The pump weight is stated on the pump nameplate. See section

4.1 Nameplate.

5.1 Lifting the pump

All lifting equipment must be rated for the purpose and checked for damage before any attempt to lift the pump. The lifting equipment rating must under no circumstances be exceeded. See section 7.4 Lifting tools.

5.2 Lifting points

Warning Never lift the pump by the power supply cables.

It may result in electric short-circuit and risk of electric shock when the pump is connected to the mains. The cables and cable entry may be damaged, leading to loss of watertightness and consequent severe damage to the motor.

5.3 Raising pump to upright position

Warnin g Make sure that the lifting brackets are tightened

before attempting to lift the pump. Tighten if necessary. Carelessness during lifting or transportation may cause injury to personnel or damage to the pump.

TM03 3034 0208TM03 3035 0208TM03 3036 0208

Fig. 4 Raising the pump to upright position, step 1

Fig. 2 Lifting points, range 72

Fig. 3 Lifting points, range 74 and 78

TM03 4459 0208TM04 6068 4809

Fig. 5 Raising the pump to upright position, step 2

Fig. 6 Raising the pump to upright position, step 3

Page 7

6. Torques, lubricants and special liquids

This section shows the screws and nuts that must be tightened to a certain torque and the lubricants to be used.

6.1 Common torques

Dimension M8 M10 M12 M16 M20 M24 M27 M30 Torque [Nm] 20 40 70 170 330 570 820 1120

6.2 Special torques and lubricants

English (GB)

Range Pos. Description Quantity Dimension

74, 78 61a O-ring (primary shaft seal) 2 - - Oil 74, 78 62 O-ring 1 - - Oil 72, 74 67 Screw (impeller) 1 M24 600 Oil

All 72a O-ring 1 - - Oil

All 105

72 105 Screw of primary shaft seal 5 - 8 -

74, 8 105 Screw of primary shaft seal 5 - 15 -

All 105b

72, 74 105b Screw of secondary shaft seal 5 - 8 -

78 105b Screw of secondary shaft seal 5 - 15 -

74, 78 153 Angular contact ball bearings 2 - - Unirex S2 / LGHP 2

All 157 O-ring 1 - - Oil All 157a O-ring 1 - - Oil All 162 Roller bearings 1 - - Unirex S2 / LGHP 2 All 154 Ball bearing 1 - - Unirex S2 / LGHP 2 All 193 Oil plug 3 R 3/4 55 ± 5 -

74, 78 756 O-ring 1 - - Oil

67 Screw (impeller) 1 M24 160 Oil

67a Screw (fastening plate of impeller) 3 - 170 Oil

O-ring (inside of stationary part) 1 - - Oil Primary shaft seal (sliding surfaces) 1 - - Silicone spray

O-ring (inside stationary part) 1 - - Oil Secondary shaft seal (sliding surfaces) 1 - - Silicone spray

Torque

[Nm]

Lubricant

Oils:

Silicone spray Valvoline: 96249498. Esso Unirex S2: 96248520/SKF LGHP 2 (-). Motor oil with viscosity grade SAE 10 W 30 or SAE 10 W 40.

6.3 Quantities of grease in bearings

Range Bearing Amount of grease

72 74 2.3 litres 78 4.2 litres

Range Bearing Amount of grease

72 74 1.0 litres 78 1.7 litres

Lower bearings

Upper bearing

2.2 litres

0.28 litres

6.4 Special liquids

Range Pos. Component Liquid

523 Cable gland for WIO Ergo 4307

All

Würth Ergo 4307 or similar (thread-locking compound) Henkel Loclite 290 or similar (thread-locking compound) ACC Silicone Silcoset 151 (glue, FM approved).

520d Moisture switch Loclite 290

177 Terminal board Silcoset 151

Page 8

7. Service tools

English (GB)

The following sections shows tools for pump service.

7.1 Standard tools

ABCD

EFGH

IJKL

Standard tools

Pos. Range Designation Description Part number

A All Pinch bar - SV5201 B All Screwdriver Straight slot C All Lock-ring pliers - SV2014 D All Plastic hammer - SV0349

72 Hook spanner (Walter) 120-130 mm -

F All Warm-air heater - G All Multimeter - H All Ratchet handle 1/2" - 96777072

I All Hexagon head driver

J All Ring/open-end spanner

K All Puller for bearing - SV0335 L All Sliding gauge 0-150 mm SV0307 M All Cable pliers - N All Feeler gauge - -

74 Hook spanner (SKF) HN22 78 Impact spanner (TMFN) 30-40 -

4 mm SV0414 M6 - 5 mm SV0296 M8 - 6 mm SV0297

M10 - 8 mm SV0298

M12 - 10 mm SV0299

M16 - 12 mm - 1/2" SV0394

8 mm SV0273

10 mm SV0083 12 mm SV0274 16 mm SV0185 20 mm 24 mm SV0122 27 mm SV0084 30 mm SV0073

Page 9

7.2 Special tools

OPQR

STUV

Special tools

Pos. Range Designation Description Part number

O All Torque wrench - P 74 Seal assembly tool (PUR127) Roplan 85 mm 96242908 Q 74 Seal assembly tool (PUR128) Roplan 95 mm 96242909 R 78 Seal assembly tool (PUR129) Roplan 110 mm 96242910 S 78 Seal assembly tool (PUR130) Roplan 110 mm 96242911 T 74 Seal assembly tool (PUR131) Roplan 100 mm 96242912 U 78 Seal assembly tool (PUR132) Roplan 120 mm 96242913 V 72 Seal assembly tool (PUR133) Roplan 65 mm 96255372

English (GB)

7.3 Tightness test tools

WXY

BAR

Tightness test tools

Pos. De sig n atio n Description Part number

W Pressure gauge --

X Test plug (KOE045)

Y Test plug (KOE171) Connector R3/4 96061213

Connector M3\8-24 UNF F-ISO

228-G 3\8M

96061209

7.4 Lifting tools

AA BB CC DD

Lifting tools

Pos. De sig n atio n Description Part number

AA Eyebolt with rotating swivel Range 74 and 78 BB Shackle All CC Eye bolt All DD Lifting clamp Range 78 98253177

Page 10

8. Service

Note

English (GB)

8.1 General information

Warning Before starting work on the pump, make sure that

the mains switch has been locked in position 0. All rotating parts must have stopped moving.

Warning Except for replacement/dismantling of bearings,

all other service work must be carried out by Grundfos or an authorised service workshop.

Service must be carried out by specially trained persons. Before carrying out maintenance and service, it must be ensured that the pump has been thoroughly flushed with clean water. Rinse the pump parts with water after dismantling.

Before assembly:

• Clean and check all parts.

• Replace defective parts with new parts.

• Order the necessary service kits.

• Gaskets and O-rings should always be replaced when the pump is overhauled.

During assembly:

• Lubricate and tighten screws and nuts to correct torque as stated in section.

8.2 Pump cleaning and visual inspection

A simple maintenance measure is to clean the pumps at regular intervals. The pumps may be cleaned on site at the pumping station when lifted up from the wet pit. Hose down the pump externally using a high-pressure jet cleaner (maximum pressure 100 bar). Caked dirt on the motor must be removed to ensure good heat conductivity. A mild detergent approved for disposal into the sewage system may be used. The pumps may be scrubbed, using a soft brush, if necessary.

Visual inspection of the pump should include search for cracks or other external damage. Inspect the lifting bracket and lifting chain for wear and corrosion. Inspect the pump cable for cracks or lacerations in the sheath, kinks or other damage. Inspect visible parts of the cable entry for cracks and for being firmly connected to the motor top cover. Check all visible screws and tighten, if necessary.

The air vent valve at the top of the cooling jacket may be removed and cleaned, if necessary. Clean the vent hole before refitting the valve after cleaning.

8.3 Annual maintenance

Pumps in normal operation should be inspected once a year. If the pumped liquid is very muddy or sandy, check the pump at shorter intervals.

The following points should be checked:

• Power consumption

See section 4.1 Nameplate.

• Oil level and oil condition

See section 8.4 Oil check and oil change.

• Cable entry

Make sure that the cables are not sharply bent or pinched. Replace the cables if necessary. See section 9.1 Checking and replacing the cable.

• Sensors

Make sure that sensor are working. Replace the sensors if necessary. See section 9.3 Replacing the protection sensors

• Impeller clearance

Check the impeller clearance. See section 8.5 Inspection and adjustment of impeller

clearance.

• Pump parts

Check the pump housing, etc. for possible wear. Replace defective parts.

• Ball bearings

Check the shaft for noisy or heavy operation (turn the shaft by hand). Replace defective ball bearings. A general overhaul of the pump is usually required in case of defective ball bearings or poor motor function. This work must be carried out by an authorized service workshop.

Warnin g On Ex pumps, the ball bearings must only be

replaced by an authorised Ex workshop.

• O-rings and similar parts

During service / replacement, it must be ensured that the grooves for O-rings and seal faces have been cleaned before the new parts are fitted.

Used rubber parts must not be reused.

Page 11

8.4 Oil check and oil change

Note

The oil chamber is filled with oil acting as lubricant and coolant for both mechanical shaft seals.

Check the oil regularly to avoid damage and breakdown of the pump.

Low oil level may indicate that the upper mechanical shaft seal is defective. Contact an authorized service workshop for further overhaul of the pump and repair, if required.

Warning Lack of oil may cause overheating and damage of

the mechanical shaft seals. The WIO sensor in the oil chamber will trip the alarm if the oil quality is poor or there is not enough oil in the oil chamber.

Use oil with viscosity grade SAE 10 W 30 or SAE 10 W 40.

Oil quantity

4. If the oil needs to be changed, remove screw C and allow all the oil to drain from the chamber into the container. Pour an oil sample into a glass container and observe the condition of the oil. Clear oil can be reused. Emulsified oil must be changed and disposed of.

Used oil must be disposed of in accordance with local regulations.

5. Replace the O-rings, refit screw C and tighten securely. Fill the oil chamber with oil to the correct level. Refit screws A and B and tighten securely.

Upright position

Proceed as follows:

1. Identify the screws A, B and C and their positions relative to each other. See fig. 7.

English (GB)

Range

72 25 litres 18.5 litres 25 litres 74 - 20 litres 25 litres 78 - 80 litres 80 litres

The oil in the oil chamber can be changed with the pump in either horizontal or upright position.

Horizontal position

Proceed as follows:

1. Place the pump in such a position that inspection screw A is pointing upwards.

Fig. 7 Pump with inspection screw A upwards

Warning When slackening the screw A of the oil chamber,

note that pressure may have built up in the chamber. Do not remove the screw until the pressure has been fully relieved!

2. Place a clean container under the pump to collect all the drained-off oil. Remove screw B and observe the oil level.

3. Check the oil level and take an oil sample to inspect the condition of the oil. The oil becomes greyish white like milk if it contains water. In normal operation a small leakage through the mechanical shaft seals is expected to happen, but if the water content in the oil is high, this may be the result of a defective shaft seal. The oil should be changed if it contains water.

Installation type

S C and D ST

Fig. 8 Correct oil level of upright pump

Warnin g When slackening the screw A of the oil chamber,

note that pressure may have built up in the chamber. Do not remove the screw until the pressure has been fully relieved!

2. Proceed as above and use screw B again for indication of the level of oil in the oil chamber. See fig. 8.

3. When the pump is upright, the oil has to be pumped out of the oil chamber. Use a suction pump with a flexible suction hose that can be inserted deep into the oil chamber.

4. Pump out the oil using all the screw holes in turns so as to reach all sections of the interior of the oil chamber. Collect the drained oil in a clean container.

TM03 1628 2705

5. Replace the O-rings, refit screw C and tighten securely. Fill the oil chamber with oil to the correct level. Refit screws A and connecting block B and tighten securely.

Used oil must be disposed of in accordance with local regulations.

TM04 6924 1210

Page 12

8.5 Inspection and adjustment of impeller clearance

Note

View from direction A

English (GB)

Position numbers of parts (digits) refer to section 11. Drawings and section 11.4Position numbers and material specification.

The correct impeller clearance is 1.3 mm ± 0.2 mm. The clearance should be reset if it is 2.0 mm or more. The method for resetting the clearance is different for dryinstalled pumps, type D, and submersible pumps, types S and C. For dry-installed pumps there are two methods. All methods are described here.

8.5.1 Submersible pumps, installation types S, C and ST

Submersible pumps have a separate adjustable pump suction cover which may be shaped as a suction bell. When the pump is installed or withdrawn, locate the six fastening screws of the suction cover and the three set screws.

Use a feeler gauge (N) to check the clearance between the impeller and the suction cover all around the perimeter of the suction opening. See fig. 9.

Warning Never work under a pump when it is hanging

from hoist!

Before adjusting the clearance, clean the gap between impeller and suction cover.

If the clearance needs adjustment proceed as follows:

1. Slacken all fastening screws (35) and set screws between suction cover and pump housing.

2. Use a rubber mallet to tap the suction cover to close the clearance.

3. Open the clearance to specified value by turning the three set screws (12c).

4. Check that the clearance is uniform around the perimeter of the suction opening.

5. Tighten the fastening screws (35) and check that the clearance is stable.

6. Turn the impeller (49) by hand and check at several points.

8.5.2 Dry-installed pumps, installation types D and H

The impeller clearance can be inspected and set with the pump installed on the pump stand and connected to the pipework. In these pumps, the suction cover is located between pump housing and outer connection flange on the suction side of the pump.

Depending on the construction, there are two ways to set the impeller clearance.

Method 1

Range Pump types

S2.90.xxx.xxxx.x.xxx.

72 and 74

S2.100.xxx.xxxx.x.xxx. S3.135.600.xxxx.x.xxx. S3.115.xxx.xxxx.x.xxx.

S3.130.xxx.xxxx.x.xxx. S3.145.xxx.xxxx.x.xxx. S4.135.xxx.xxxx.x.xxx.

Fig. 9 Impeller clearance, installation types S, C and ST

Fig. 10 Impeller clearance, installation types D and H,

method 1

These pump types have threaded holes for the fastening screws (35) of the suction cover (12a) in the pump housing (50) as shown in fig. 10. Set the impeller (49) clearance as follows:

1. Slacken the three set screws (12c) and close the impeller

TM03 3362 0506

clearance "S" by tightening the six fastening screws (35) diagonally to move the suction cover evenly.

Warnin g Do not use too much force when tightening the

fastening screws as this may damage the bearings. The movement is usual 1 to 3 mm.

2. Measure the distance "L" between suction cover and pump housing at three points, next to the set screws, using feeler gauges or callipers and make a note of the distance.

3. Slacken the fastening screws and draw back the suction cover by 1.3 mm ± 0.2 mm using the three set screws (approx. one 150 ° turn of an M27 set screw) and the distance "L" as reference.

4. Tighten all fastening screws and check that the distance "L" at the three reference points is stable on the new value.

TM03 3073 0206

Page 13

Method 2

View from direction A

Note

Caution

Note

Range Pump types

S3.110.xxx.xxxx.x.xxx.

72 and 74

S3.120.xxx.xxxx.x.xxx. S3.135.500.xxxx.x.xxx.

Fig. 11 Impeller clearance, installation type D and H, method 2

9. Dismantling and assembly instructions

Position numbers of parts (digits) refer to section 11. Drawings and section 11.4 Position numbers and material specification, and position numbers of tools (letters) refer to section 7. Service

tools.

9.1 Checking and replacing the ca ble

Make sure that the cables are not sharply bent or pinched and that the cable sheath has no visual defects.

Warnin g In case of repairs, always use original service

parts from the manufacturer.

Cable change

There are two different methods of changing the cables. Both methods are described here.

Do not disassemble the cable entry unless you are going to replace it.

Disconnecting the cables will shorten them significantly.

9.1.1 Change of cable without adapter flange, method A

TM03 3074 0206

English (GB)

These pump types have threaded holes in the suction cover (12a) for the fastening screws (35) as shown in fig. 11. Set the impeller clearance as follows:

1. Slacken the six fastening screws (35) and close the impeller clearance "S" by tightening the three set screws (12C). Tighten the screws diagonally to move the suction cover evenly.

Warning Do not use too much force when tightening the

fastening screws as this may damage the bearings. The movement is usual 1 to 3 mm.

2. Measure the distance "L" between suction cover and pump housing at three points, next to the set screws, using feeler gauges or callipers and make a note of the distance.

3. Slacken the set screws and draw back the suction cover by

1.3 mm ± 0.2 mm using the six fastening screws (approx. one 270 ° turn of an M12 fastening screw) and the distance "L" as reference.

4. Tighten all set screws and check that the distance "L" at the three reference points is stable on the new value.

TM05 6812 5212 - TM05 6813 5212

Fig. 12 Cable entry without adapter flange attached to motor

top cover (left) and cable entry (right)

Disconnecting the old cable

1. Remove the screws (180a). See fig. 12.

2. Remove the cable clamp (180).

3. Remove the screws (181a).

4. Pull the cable out of motor top cover/terminal box (151/164a).

5. Remove the cable entry (168) including the rubber seal (198) from the cable (181).

6. Remove the rubber seal (198) from the cable entry (168).

Connecting the new cable

1. Slide cable entry (168) on to cable.

2. Slide rubber seal (198) on to cable.

Make sure that the washer is below the rubber seal and fitted against the cable entry.

Not all rubber seals include the washer (especially pumps manufactured before 2010).

3. Fit the cable entry to the motor top cover/terminal box (151/ 164a) with screws (181a).

4. Fit the cable clamp (180a) to the cable entry (168) with screws (180a).

To prepare a new cable (length of leads, cable clips, cable markings, etc.), please use the old cable as reference.

Connect according to the wiring diagram.

Page 14

9.1.2 Change of cable with adapter flange, method B

Note

English (GB)

9.2 Replacing the terminal board

Warnin g Do not change the terminal board unless it is

damaged or it is absolutely necessary.

Please note that the position numbers below refer exclusively to the replacing of the terminal board.

Fig. 13 Cable entry with adapter flange

Disconnecting the old cable

1. Disconnect the cables from the terminal box (164a).

2. Remove the screws (180a). See fig. 13.

3. Remove the cable clamp (180).

4. Remove the screws (183).

5. Pull out the cable including adapter flange (168a), rubber seal (198) and cable entry (168).

6. Remove the screws (181a).

7. Pull out the adapter flange (168a).

8. Pull out the cable entry (168) including the rubber seal (198).

9. Remove the rubber seal (198) from the cable entry (168).

Connecting the new cable

1. Slide cable entry (168) on to cable.

2. Slide rubber seal (198) on to cable.

Make sure that the washer is below the rubber seal and fitted against the cable entry.

3. Slide adapter flange (168a) on to cable.

4. Fit the screws (181a).

5. Fit the cable clamp (180a) on the cable entry (168) with screws (180a).

6. Fit the cable to motor top cover/terminal box (151/164a).

To prepare a new cable (length of leads, cable clips, cable markings, etc.), please use the old cable as reference.

Pos. Description Dimension

1 Copper stud bolt* - 2Sleeve - 3 Washer plate (round) - 4 Plastic bar - -

Washer plate

(rectangular)

6 Washer plate (square) - 7 Locking plate (round) - 8 Locking plate (square) - -

TM05 6811 5211

9Brass bolt M8 10 Brass screw M12 12 11 Brass nut M8 20 12 Brass nut M12 16 13 Brass nut M16 40 14 Brass nut M20 60 15 Spring washer M8 16 Spring washer M10 17 Spring washer M12 18 Spring washer M16 19 Washer plate M24 20 O-ring 12.0 x 3 21 O-ring 19.2 x 3 22 O-ring 24.0 x 3.53 23 O-ring 34.2 x 3.53 24 Glue (Silcoset 151) - -

* Range 74 pumps manufactured between 1995 and 1997 may

have brass stud bolts.

Torque

[Nm]

Connect according to the wiring diagram.

Page 15

9.2.1 Range 72

Tightening torque 16 Nm

Cable side

Stator side

Note

Threaded joint, threads

engaged > 5 mm

Glued joints, shortest path through joint > 10 mm

Upper bearing bracket

Creepage distance > 16 mm

Tightening torque 16 Nm

Cable side

Stator side

Threaded joint, threads

engaged > 5 mm

S pumps, range 72, have two types of terminal board, standard and Ex. Changing method for both types are described here.

Standard terminal board, method 1

Fig. 14 Standard terminal board, range 72

Dismantling the terminal board

1. Remove the brass nuts (12) and the spring washers (10) from cable side. See fig. 14.

2. Release the locking of the brass nuts (12) on the stator side by bending down the tabs of the locking plates (8). Remove the brass nuts (12) and the plates (8).

3. Remove the washers (3 and 5) including the O-rings (20).

4. Remove the plastic bars (4) including O-rings (22) from both sides.

5. Remove the copper stud bolts (1) including sleeves (2).

Assembling the terminal board

1. Fit the copper stud bolts (1) into the sleeves (2) and fit them to the bottom of the upper bearing bracket (61c).

2. Fit the O-rings (22) around the sleeves (2).

3. Fit the plastic bars (4).

4. Fit the washers (3 and 5) including O-rings (20) to the copper stud bolts (1) on the both sides. Fit the locking plates (8) and brass nuts (12) on the stator side. Bend one tab of the locking plates (8) against the nuts (12) to lock the nuts.

5. Connect according to the wiring diagram, use spring washers (10) and brass nuts (12).

Ex terminal board, method 2

TM05 6798 5212

Fig. 15 Ex terminal board, range 72

Dismantling the terminal board

Warnin g Ex terminal board parts have been glued

together. You might need to use more force in removing than normally.

Ex terminal board parts cannot be reused.

1. Remove the brass nuts (12) and the spring washers (17). Disconnect the cables from both cable and stator sides. See fig. 15.

2. Release the locking of the brass nuts (12) on the stator side by bending down the tabs of the locking plates (8).

3. Remove the washers (5) including the O-rings (20).

4. Remove the copper stud bolts (1) including washers (3).

5. Remove the sleeves (2).

Upper bearing bracket (61c) must be cleaned carefully before assembly.

Assembling the terminal board

1. Fit the copper stud bolts (1) into sleeves (2) and fit them to the bottom of the upper bearing bracket (61c).

Use glue, such as Silcoset 151.

2. Apply glue to the bottom of the plastic bars (4) and fit to upper bearing bracket (61c) on the cable side.

3. Apply glue to the bottom of the washers (3) and fit them to the plastic bars (4).

4. Fit the O-rings (22) around the sleeves (2) on the stator side.

5. Fit the plastic bars (4) on the upper bearing bracket (61c) on the stator side. Fit the locking plates (8) and brass nuts (12). Lock the nuts by bending one tab of locking plates (8) towards the brass nuts (12).

6. Connect according to the wiring diagram, use spring washers (17) and brass nuts (12).

English (GB)

TM05 6799 5212

Page 16

9.2.2 Range 74 and 78

Stator side

English (GB)

For S pumps, range 74 and 78, there are two main types of terminal board depending on pump manufacturing year and model. Changing methods for all are described here.

Pumps manufactured between 1995 and 1997

Fig. 16 Terminal board for pumps manufactured between 1995

and 1997, range 74 and 78

Dismantling the terminal board

1. See fig. 16.

2. Disconnect the cables from cable side by removing nuts (11), bolts (9), washer plates (5) and spring washers (15).

3. Disconnect the cables from stator side by removing nuts (13) and spring washers (18).

4. Remove the nuts (13) and locking plates (7).

5. Remove the plastic bars (4) and washers (3).

6. Remove washers (19).

7. Remove the copper stud bolts (1) and sleeves (2) including Orings (21 and 23).

Assembling the terminal board

1. Fit the O-rings (21 and 23) and lubricate with silicone spray

2. Fit the copper stud bolts (1) in the sleeves (2) fit them to wall.

3. Fit washers (3 and 19).

4. Fit the plastic bars (4).

5. Fit the washers (7) and nuts (13).

6. Connect the cables on the stator side according to the wiring diagram. Use brass nuts (13) and washers (18).

7. Connect the power cables on the cable side according to the wiring diagram. Use brass bolts (9), nuts (1) and washers (5 and 15).

Pumps manufactured after 1997

Fig. 17 Terminal board for pumps manufactured 1997 and

later, range 74 and 78

Dismantling the terminal board

1. See fig. 17.

TM05 6817 0113

2. Disconnect the cables from the cable side by removing nuts (10) and spring washers (17).

3. Disconnect cables from the stator side by removing nuts (13) and spring washers (18).

4. Release the locking of the nuts (14) by bending down the tabs of the locking plates (8).

5. Remove the nuts (14).

6. Remove the locking plates (8) and washers (6).

7. Remove the copper stud bolts (1), washer plates (19) and sleeves (2) including O-rings (21 and 23).

Assembling the terminal board

1. Fit the O-rings (21 and 23) and lubricate with silicone spray.

2. Fit the plastic bars (4) to the wall in the terminal box.

3. Fit the copper stud bolts (1) including sleeves (2) and washers (19).

4. Fit the washers (6) and the locking plates (8).

5. Fit the nuts (14) and tighten with a torque of 60 Nm.

6. Lock the nuts (14) by bending up one tab of the washers (8).

7. Connect the cables on the stator side according to the wiring diagram.

8. Connect the cables on the cable side according to the wiring diagram.

TM05 6818 0113

Page 17

9.3 Replacing the protection sensors

Spade connectors

Mounting screw and lock

washer

Screw

Mounting bracket

Caution

Pt100 in stator

Pt100 in upper bearing

9.3.1 Moisture switch

The pumps can have up to three moisture switches, two in the terminal box (164a) and one on the lower bearing bracket (155).

The changing method is the same, no matter where the switch is placed.

Warning Do not touch the head of the moisture switch with

wet or oily hands. Moisture on the sensor head before installation will cause false measuring values.

Fig. 18 Moisture switch on lower bearing bracket

Removing the moisture switch

1. Disconnect the spade connectors from the switch.

2. Remove the mounting screw and lock washer from the mounting bracket. Remove the switch from the base of the terminal box/upper bearing bracket (164a/61c).

3. Remove the screw.

4. Remove the switch from the mounting bracket.

Fitting new moisture switch

5. Fit the moisture switch to the mounting bracket.

6. Fit the screw to attach the switch to the mounting bracket.

7. Fit the mounting bracket including the switch on the base with the mounting screw and the lock washer.

8. Connect the spade connectors.

9. Connect the wires according to the wiring diagram. See section 11.6 Electrical connections.

9.3.2 Pt100 sensor in upper bearing bracket

Fig. 19 Pt100 in upper bearing and in stator

Removing Pt100

1. Cut the wire of the Pt100 sensor right next to sensor.

2. Drill out the sensor from the upper bearing bracket (61c).

Fitting new Pt100

3. Dip the sensor head in glue and insert it into the hole in the upper bearing bracket (61c).

TM05 6578 4912

4. Connect according to the wiring diagram. See section

11.6 Electrical connections.

9.3.3 Pt100 sensor on the stator

Removing Pt100

1. Cut the wire of the Pt100 sensor right next to sensor and remove the wire. See fig. 19.

2. Leave the old sensor on the stator (48).

Fitting new Pt100

Warnin g Make sure that the wire of new sensor is

protected by a protection sleeve.

3. Glue the sensor on to stator windings (48).

4. Connect according to the wiring diagram. See section

11.6 Electrical connections.

English (GB)

TM05 6476 4812

Page 18

9.3.4 Pt100 sensor in lower bearing bracket

Quick connector

59a

155

Glue point of Pt100

155

WIO sensor

Connecting

block

155

English (GB)

Pt100 in lower bearing bracket can be fitted in three places depending on pump manufacturing year. In pumps manufactured before 2012, sensors are fitted to the locking ring (59a) and lower bearing bracket (155). See fig. 20. One sensor can be fitted to the lower bearing bracket (155), but in a different place, see fig. 21. There are two methods for changing the sensors, and both methods are described here.

Method A

Removing Pt100

1. See fig. 21. Pull out the sensor using a pair of tongs.

2. Clean the sensor hole carefully.

Fitting new Pt100 sensor in the lower bearing bracket

3. Insert the sensor into the hole in the lower bearing bracket (155).

4. Spread glue around the sensor end, see fig. 21.

5. Connect according to the wiring diagram. See section

11.6 Electrical connections.

9.3.5 Water-In-Oil sensor (WIO)

Fig. 20 Pt100 sensor positions in the lower bearings

Removing Pt100

1. See fig. 20. Cut the wire of the Pt100 right next to the sensor.

2. Drill out the sensor from the locking ring/bearing bracket (59a/

155).

3. Clean the area with pressurised air.

Fitting new Pt100

4. Dip the whole sensor in the glue and insert it into the hole in locking ring/bearing bracket (59a/155).

5. Apply a small amount of glue to root of sensor to make sure that it sticks.

6. Connect according to the wiring diagram. See section

11.6 Electrical connections.

Method B

TM05 6470 4812TM05 6471 4812

TM05 6099 4512

Fig. 22 Water-In-Oil sensor (WIO)

Removing the WIO sensor

1. See section 9.4.10 Removing the rotor.

2. Remove the sensor from the bracket on lower bearing bracket (155).

3. Open the cable gland.

4. Remove the wires from the connecting block.

5. Pull the sensor cable out through the cable entry in the lower bearing bracket.

Fitting new WIO sensor

1. Fit the sensor in the bracket.

2. Put the sensor cable up through the cable entry in the lower bearing bracket.

3. Tighten the cable gland.

4. Cut the cable to a suitable length and connect the wires to the connecting block. Connect according to the wiring diagram. See section 11.6 Electrical connections.

Fig. 21 Pt100 in lower bearing bracket on pumps

manufactured after 2010

Page 19

9.4 Dismantling range 72

Note

190

164a

173

173b

61c

178

176a

176

164

176c

166

157a

177a

055

759

760

154

177

61c

183

157

For position numbers, see section 11.1 Range 72.

Warning Maintenance and service work on explosion

proof pumps must be carried out by Grundfos or a service workshop authorised by Grundfos.

9.4.1 Removing the impeller and pump housing

Before dismantling, support the pump from lifting bracket with hoist and beneath the discharge flange with wedges.

1. Remove the outer screws (26).

2. Lift the pump including the impeller (49) and intermediate ring (1) out of the pump housing (50). Use wedges, if necessary.

3. Remove the O-ring (39a).

4. Place the motor with impeller in horizontal position on for instance a stable trestle.

5. Remove the O-ring (37b).

6. Support the impeller with a lifting strap, board and hoist to prevent movement.

7. Bend out the locking tab in the cap (66) and loosen the impeller screw (67) but do not remove the screw yet.

8. Remove the impeller (49), use wedges, if necessary.

9. Remove the impeller screw (67), the O-ring (67b), the cap (66) and the O-ring (62a).

10. Remove the impeller (49).

11. Remove the key (9a).

9.4.2 Draining the oil

1. See section 8.4 Oil check and oil change

9.4.3 Removing the primary shaft seal

1. See section 9.4.1 Removing the impeller and pump housing.

2. See section 9.4.2 Draining the oil.

3. Loosen the set screws in the shaft seal (105) and remove the rotating part.

4. Gently remove the stationary ring of the shaft seal (105).

9.4.4 Removing the terminal box

Fig. 23 Terminal box, range 72

1. See section 9.4.3 Removing the primary shaft seal

2. Place the motor in vertical position on for instance a stable trestle (shaft downwards).

3. Remove the screws (166). See fig. 23.

4. Remove the terminal box cover (164) including O-ring (165).

5. Remove the screws (173) and locking plate (173b).

6. Disconnect the power cable wires (181) from the terminal board (177) on upper bearing bracket (61c).

7. Disconnect protection sensor cables from the terminal block (176a). Do not disconnect the control cable wires from the terminal block.

8. Straighten the corners of the locking plate (173b) and remove the screws (173) and the locking plate.

9. Disconnect the control cable (252) earth conductors.

10. Remove the outer screws (178).

11. Lift off the terminal box (164a).

9.4.5 Removing the cooling jacket

1. Remove the screws (150a).

2. Remove the cooling jacket (150c) using a hoist by lifting from the lifting eyes on both sides of the cooling jacket. Remove the O-rings (37a and 157b).

9.4.6 Removing the upper bearing bracket

Fig. 24 Upper bearing bracket, range 72

1. See section 9.4.4 Removing the terminal box.

2. See section 9.4.5 Removing the cooling jacket.

3. Remove the screws (183) and fit them in the holes in the upper bearing bracket (61c).

4. Loosen the bearing bracket by driving the four screws (183) against the end of the stator housing. Screws will push the bearing bracket up from the stator housing (55).

5. Pull the upper bearing bracket (61c) approximately 20 cm out of the stator housing.

6. Disconnect the sensor cables from the terminal board (177) under upper bearing bracket (61c).

7. Disconnect the cables by removing the screws and locking plates from the terminal board (177) under the upper bearing bracket. See fig. 24.

8. Remove the upper bearing bracket (61c) including O-rings (157a and 157) from the stator housing (55).

9. Remove the moisture absorbing bag (760) from the protection ring (759).

10. Remove the protection ring (759) including protection sleeve (177a).

9.4.7 Removing the upper bearing

1. See section 9.4.6 Removing the upper bearing bracket

2. Gently heat up the inner ring of the roller bearing and remove

TM05 6770 5112

the bearing (154) with a bearing puller (K).

English (GB)

TM05 6769 5112

Page 20

9.4.8 Removing the shaft seal housing

Note

105b058 272184

055

Note

English (GB)

9.4.11 Removing the lower bearings

1. See section 9.4.10 Removing the rotor.

2. See fig. 26. Disconnect the cable gland (523) in the lower bearing bracket cover.

3. Disconnect the bearing sensor and remove the cable gland from the upper bearing bracket cover (60).

4. Remove the screws (182b) and remove upper bearing bracket cover (60) of the lower bearing bracket. Leave the cover lying against the stator windings.

5. Loosen and remove the screws (182a).

6. Remove the lower bearing bracket cover (59) of the lower bearing bracket and remove the O-ring (109).

7. Remove the lock nut (270), lock washer (271) and angle ring (269).

8. Remove the lower bearing bracket (155) using a hoist.

Fig. 25 Removing the shaft seal housing, range 72

1. See section 9.4.3 Removing the primary shaft seal.

2. Place the motor in horizontal position on for instance a stable trestle or other support.

3. Remove the vent pipe (272) from the stator housing (55).

4. Secure the shaft seal housing (58) with the lifting strap and remove screws (184).

5. Remove the shaft seal housing (58) including the vent pipe (272).

9.4.9 Removing the secondary shaft seal

1. See section 9.4.8 Removing the shaft seal housing.

2. Loosen the set screws in the secondary shaft seal (105b). Remove the rotating and stationary parts of the shaft seal (105b).

9.4.10 Removing the rotor

TM05 6768 5112TM05 6802 5212

The outer ring of the roller bearing and the rolls will be removed together with the bearing bracket.

9. Collect the springs (153a).

10. Check that the pin (59b) is attached to the lower bearing bracket.

11. Gently heat up the inner ring of the roller bearing (162) and remove the ring from the shaft.

12. Gently heat up the outer ring of the roller bearing (162) and remove the ring from the lower bearing bracket (155).

13. Remove the supporting ring (197) from the shaft.

14. Heat the locking ring (59a) to 200 °C and remove it.

15. Remove the angular contact ball bearings (153) from the shaft.

16. Remove the upper bearing bracket cover (60) of the lower bearing bracket from the shaft.

Fig. 26 Rotor, range 72

1. See section 9.4.9 Removing the secondary shaft seal.

2. Remove the screws (184a).

3. Pull the rotor (172) with the lower bearing bracket (155) approximately 15 cm out of the stator housing to be able to disconnect the sensors from the connecting block.

Support the rotor by placing boards between the stator housing and the rotor.

4. Disconnect the sensors from the connecting block.

5. Remove the rotor and place it in vertical position (shaft upwards) on for instance a stable trestle.

Page 21

9.5 Assembling range 72

Note

52.2 ± 0.5 56 ± 0.5 68 ± 0.5

Assembly tool PUR133

∅ 80.4

∅ 85

O-rings

9.5.1 Fitting the lower bearings

1. Place the motor in vertical position on for instance a stable trestle (shaft seal upwards).

2. Fill the upper bearing bracket cover (60) with grease and fit the cover on the rotor. See section 6.3 Quantities of grease in bearings.

3. Grease the angular contact ball bearings (153). Fill only 50 % of the free space of the bearings.

4. Heat up the greased angular contact ball bearings (153) to 120 °C and fit them on the shaft. For the angular contact bearing to absorb the axial forces, the bearing must be fitted so that the large surface of the inner ring is resting on the bearing shoulder of the shaft and the large surface of the outer ring is resting on the locking ring (59a).

5. Heat the locking ring (59a) to 180 °C and fit it on the bearings (153).

6. Fit the springs (153a) in the holes of the locking ring.

7. Fit the supporting ring (197) on the rotor.

8. Heat the inner ring of roller bearing (162) to 120 °C and fit it on the rotor.

9. Fit the outer ring of roller bearing (162) on to the lower bearing bracket (155).

10. Grease the roller bearings (162). Fill only 50 % of the free space of the bearings.

11. Check that the pin (59b) and the Pt100 sensor are fitted on the lower bearing bracket (155).

12. Fit the lower bearing bracket (155) on the rotor.

13. Fit the angle ring (269), lock washer (271) and nut (270) on the rotor.

Check that the locking ring and the outer ring of the bearings can be rotated without any disturbances.

14. Bend one wing of the lock washer (271) into the notch of lock nut (270).

15. Fit the O-ring (109) in the groove of the lower bearing bracket (155).

16. Fit the lower bearing bracket cover (59) on the lower bearing bracket (155) with screws (182a).

17. Fit the upper bearing bracket cover (60) on the lower bearing with screws (182b).

9.5.2 Fitting the rotor

1. Fit the O-ring (72) on the lower bearing bracket (155).

2. Lower the rotor with shaft into the stator (55), leaving a space of approximately 20 cm.

3. Connect the sensor connecting block.

4. Complete the fitting of the rotor/shaft.

5. Fit the screws (184a).

9.5.3 Fitting the secondary shaft seal

English (GB)

TM05 6278 4612

Fig. 27 Fitting the secondary shaft seal, range 72

1. Place the motor in horizontal position on for instance a stable trestle.

2. Clean the shaft.

3. Fit the O-ring on the stationary part of the secondary shaft seal (105b).

4. Fit the O-ring inside the stationary part of the secondary shaft seal (105b).

5. Lubricate the moving parts with silicone spray.

6. Fit the stationary part of the secondary shaft seal (105b) on the shaft and press it home (V). See fig. 27.

7. Tighten the set screws in the secondary shaft seal (105b) with a torque of 8 Nm.

8. Check the setup length (2 mm) and the assembly length (56 ±

0.5 mm) of the secondary seal (L).

9.5.4 Fitting the shaft seal housing

1. Fit the O-ring (72a) on the lower bearing bracket (155).

2. Fit the O-ring (37c) in the groove of the shaft seal housing (58).

3. Secure the shaft seal housing (58) including the air went pipe with the lifting strap and fit it to the stator housing (55).

4. Fit the screws (184).

5. Attach the air went pipe (272) on the stator housing (55).

9.5.5 Fitting the upper bearing

1. Place the motor in vertical position on for instance a stable trestle (shaft seal downwards).

2. Heat the upper bearing (154) to 120 °C and fit on the shaft.

3. Grease the upper bearing (154). Fill only 50 % of the free space of the bearing with grease. See section 6.3 Quantities of grease in bearings.

Page 22

9.5.6 Fitting the upper bearing bracket

Note

61.2 ± 0.5 65 ± 0.5 77 ± 0.5

Assembly tool PUR133

∅75

∅80

O-rings

English (GB)

1. Check that the protection sleeves are placed against the protection ring (759).

2. Take the stator cables and protection sensor cables trough the protection sleeves.

3. Fit the protection ring (759) to the stator housing (55).

4. Fit the upper bearing bracket (61c) into the stator housing (55), leaving a space of approximately 20 cm.

5. Fit the O-ring (157) to the upper bearing bracket (61c).

6. Connect the stator wires to the terminal board (177) according to the wiring diagram. Fit the wires, spring washers and screws. Tighten the screw with a torque of 16 Nm.

7. Connect the protection sensor wires according to the wiring diagram.

8. Fit the moisture absorbing bag (760) to the protection ring (759).

Upper bearing bracket must be closed within one hour after the new moisture absorbing bag has been exposed to atmospheric humidity.

9. Complete the fitting of the upper bearing bracket and fit screws (183).

10. See section 10.1 Tightness test of stator (submerged).

9.5.7 Fitting the cooling jacket

This section applies only to pumps with cooling jacket.

1. Fit the O-ring (37a) on the lower bearing bracket (155).

2. Fit the O-ring (157b) in the groove of the stator housing (55).

3. Fit the cooling jacket (150c) by lifting with a hoist from the lifting eyes on both sides of the cooling jacket.

4. Fit the screws (150a).

9.5.8 Fitting the terminal box

1. Fit the O-ring (157a).

2. Fit the terminal box (164a) on the stator housing using a hoist.

3. Fit the screws (178).

4. Connect the power cable earth conductors on the upper bearing bracket (61c) with locking plate (173b) and screws (173). Bend one corner of the locking plate towards the screw.

5. Connect the protection sensor cables coming from the motor side to the terminal block (176a).

6. Connect the power cables to the terminal board (177) with spring washers and screws.

7. Fit the O-ring (165) to the terminal box cover (164).

8. Fit the terminal box cover (164) including the O-ring (165) to the terminal box (164a).

9. See section 10.2 Tightness test of terminal box (cable side, submerged).

9.5.9 Fitting the primary shaft seal

TM05 6277 4612

Fig. 28 Fitting the primary shaft seal, range 72

1. Place the motor in horizontal position on for instance a stable trestle.

2. Make sure that the shaft is clean and smooth.

3. Lubricate the sliding surfaces with silicone spray.

4. Fit the O-ring on the stationary part of the primary shaft seal (105).

5. Fit the stationary part on the primary seal (105) on the shaft.

6. Check that the O-ring is fitted inside the rotating part of the primary shaft seal.

7. Fit the rotating part of the primary shaft seal on the shaft and press it home (V). See fig. 28.

8. Tighten the set screws in the primary shaft seal (105) with a torque of 8 Nm.

9. Check the setup length (2 mm) and the assembly length (65 ±

0.5 mm) of the primary shaft seal (L).

10. See section 10.1.1 Tightness test of shaft seal housing (submerged).

Tightness of complete motor must be verified through a submersion test.

Page 23

9.5.10 Oil filling

Note

Cable side

Stator side

1. See section 8.4 Oil check and oil change.

9.5.11 Fitting the impeller and the pump housing

1. Fit the key (9a).

2. Lubricate the cone of the shaft slightly.

3. Fit the O-ring (62a) in the groove of the cap (66). Lubricate the O-ring.

4. Fit the O-ring (67b) in the groove of screw (67). Lubricate the thread and the screw head slightly.

5. Support the impeller (49) with a hoist and fit it to the lower bearing bracket (155).

6. Fit the cap (66) including O-ring (62a) and the screw (67) including O-ring (67b). Tighten the screw with a torque of 570 Nm.

The new impeller may be higher than the old impeller, so open the impeller clearance before fitting the pump housing.

7. Place the motor in vertical position on for instance a stable trestle (shaft seal downwards).

8. Fit the O-ring (37).

9. Mount the motor on the pump housing.

10. Fit the outer screws (26) and tighten them.

11. Check the impeller clearance. See section 8.5 Inspection and

adjustment of impeller clearance.

9.6 Dismantling range 74

For position numbers, see section 11.2 Range 74.

Warning Maintenance and service work on explosion

proof pumps must be carried out by Grundfos or a service workshop authorised by Grundfos.

9.6.1 Removing impeller and pump housing

9.6.3 Removing the primary seal

1. See section 9.6.1 Removing impeller and pump housing.

2. See section 9.6.2 Draining the oil.

3. Loosen the set screws in the shaft seal (105) and remove the rotating part.

4. Gently remove the stationary ring of the shaft seal (105).

Lever the stationary ring out of the shaft seal by inserting screwdrivers in positions 0 °, 90 °, 180 ° and 270 °.

9.6.4 Removing the motor top cover

English (GB)

Before dismantling, support the pump unit from the lifting bracket with hoist and beneath the discharge flange with wedges.

1. Remove the outer screws (26).

2. Lift the pump including the impeller (49) out of the pump housing (50) using a hoist. Use wedges, if necessary.

3. Place the motor with impeller in horizontal position on for instance a stable trestle.

4. Remove the O-ring (37b).

5. Support the impeller with a lifting strap, board and hoist to prevent movement.

6. Bend out the locking tab in the cap and loosen the impeller screw (67), but do not remove the screw yet.

7. Remove the impeller (49), use wedges if necessary.

8. Remove the impeller screw (67), the cap (66) and the O-ring (62a).

9. Remove the impeller (49).

10. Remove the key (9a).

9.6.2 Draining the oil

11. See section 8.4 Oil check and oil change.

TM05 6804 5212

Fig. 29 Terminal box, range 74

1. Remove the screws (166) from the terminal box cover (164) on the cable side. See fig. 29.

2. Remove the terminal box cover (164) from the terminal box (164a) including the O-ring (165).

3. Disconnect the control cable wires (252) from the terminal block. See fig. 30.

4. Remove the screws and the spring washers from the terminal block bracket.

5. Remove the terminal block including the bracket. Leave the terminal block and bracket suspended from wires coming through the partition wall.

The terminal block is connected to the protection sensor wires coming through the partition wall.

6. Remove the brass nuts and the spring washers from the terminal board (177) on the cable side. Disconnect the power cables (181).

Page 24

English (GB)

Note

252 181

Terminal block

bracket

Partition wall of terminal box

177

Earth conductor

Brass nut and

spring washer

Cable side

Screw and

locking plate

Stator side

181

Note

Caution

Note

Fig. 30 Terminal block in terminal box, cable side

7. Bend down the corner of the locking plate, remove the screws and the plate.

8. Disconnect the earth conductors of the power cable (181).

9. Support the lifting bracket (190) with a hoist, remove screws (190b) and remove the lifting bracket.

10. Support the cables with a hoist.

11. Remove the screws (183).

12. Remove the motor top cover (151).

13. Remove the O-ring (157a). In order to change the cables, see section 9.1 Checking and replacing the cable.

9.6.5 Removing the cooling jacket

This section applies only to pumps with cooling jacket.

1. See section 9.6.4 Removing the motor top cover.

2. Place the motor in vertical position on for instance a stable trestle (shaft seal downwards).

3. Remove the screws (150a).

Step 4 applies only to pumps with a locking ring.

4. Remove the locking ring (754) with a hoist.

5. Remove the cooling jacket (150c) by lifting the pump with a hoist from the lifting eyes on both sides of the cooling jacket.

6. Remove the O-rings (37a and 157b).

9.6.6 Removing the terminal box

1. See section 9.6.4 Removing the motor top cover.

2. See section 9.6.5 Removing the cooling jacket.

3. Remove the screws (166) from the terminal box cover (164) on the stator side. See fig. 31.

4. Remove the terminal box cover (164) including the O-ring (165) from the terminal box (164a).

5. Disconnect the protection device cables from the terminal block.

The terminal block is connected to the protection sensor wires coming through the partition wall.

6. Disconnect the power cables (181) from the terminal board (177) by removing the hexagon head screws (10) and washers (11).

7. Remove the screws (178a or 178 in models without intermediate ring).

8. Remove the terminal box (164a) including the intermediate ring (755) using a hoist.

Lift the terminal box carefully to avoid damage to

TM06 0655 0614

the cables.

Step 9 applies only to pumps with intermediate ring.

9. Remove the O-ring (756) from the intermediate ring (755).

9.6.7 Removing the upper bearing

1. Heat up (max. 110 °C) the inner ring of the roller bearing and pull off the bearing including the bearing housing (61).

2. Remove the circlip (61b).

3. Remove the O-rings (61a) from the outer wall of the bearing housing (61).

4. Turn the bearing housing (61) so that the roller bearing (154) is underneath it. Gently heat up (max. 110 °C) the bearing housing (61) and remove the roller bearing (154).

9.6.8 Removing the shaft seal housing

1. Place the motor in vertical position on for instance a stable trestle (shaft seal upwards).

2. Remove the screws (184).

3. Remove the shaft seal housing (58) with a hoist. If the connection is tight, knock gently with a rubber hammer to ease the separation.

9.6.9 Removing the secondary shaft seal

1. Loosen the set screws in the secondary shaft seal (105b).

2. Carefully remove the rotating part of the shaft seal (105b).

3. Gently remove the stationary ring of the shaft seal (105b).

Lever the stationary ring out of the shaft seal by inserting screwdrivers in positions 0 °, 90 °, 180 ° and 270 °.

Fig. 31 Terminal box (without motor top cover), range 74

TM05 6803 5212

Page 25

9.6.10 Removing the rotor

Note

1. Remove the screws (184a).

2. Loosen the lower bearing bracket (155) from the stator housing (58) by pushing components apart from each other with bolts. Lift the rotor (172) at the same time, but no higher than approximately 10 cm out of the stator housing.

3. Secure lower bearing bracket with boards, and disconnect the connecting block.

4. Remove the rotor assembly and place it in vertical position (shaft upwards) on for instance a stable trestle.

9.6.11 Removing the lower bearings

Fig. 32 Rotor, range 74

1. Remove the screws (182b). See fig. 32.

2. Separate the upper bearing bracket cover (60) from the lower bearing bracket by pushing components apart from each other with bolts (182b). Leave the cover on to stator wings.

3. Remove the screws (182a).

4. Remove the lower bearing bracket cover (59).

5. Remove the O-ring (109).

6. Bend the tab of the lock washer (271) out of the notch in the lock nut (270).

7. Remove the lock nut (270), lock washer (271) and angle ring (269).

8. Remove the lower bearing bracket (155) with a hoist and remove O-ring (72a).

The outer ring of roller bearing and the rolls will be removed together with the bearing bracket.

9. Remove the outer ring of roller bearing from lower bearing bracket by lightly tapping the outer wall of the bearing.

10. Remove the springs (153a).

11. Gently heat up the roller race of the bearing (162) and remove it.

12. Remove the supporting ring (197).

13. Heat the locking ring (59a) up to 200 °C to loosen it. Remove the ring.

14. Remove the angular contact ball bearings (153) from the shaft.

9.7 Assembling range 74

9.7.1 Fitting the lower bearings

1. Place the rotor in vertical position (shaft upwards) on for instance a stable trestle.

2. Grease the angular contact ball bearings (153) and the roller bearing (162). Fill only 50 % of the free space of the bearings. See section 6.3 Quantities of grease in bearings.

3. Fill the bottom of the upper bearing bracket cover (60) with grease and fit it on the shaft.

Step 4 applies only to pumps that have a labyrinth seal.

4. Heat the labyrinth seal (60a) up to 120 °C and fit it on the shaft.

5. Heat the greased angular contact ball bearing (153) up to 120 °C and fit it on the shaft.

6. Fit the supporting ring (197) on the shaft.

7. Heat the inner ring of the roller bearing (162) up to 120 °C and fit it on the shaft.

Let rotor and bearing cool down before continuing.

8. Heat the locking ring (59a) up to 180 °C and fit it on the shaft.

Let rotor and bearing cool down before continuing.

9. Fit the six springs (153a) in the locking ring (59a).

10. Fit the roller bearing (162) on the lower bearing bracket (155).

11. Make sure that the pin (59b) is inserted in the hole in the lower bearing bracket (155). Fit the lower bearing bracket (155) on the shaft.

12. Fit the angle ring (269) on the rotor.

13. Fit the lock washer (271) on the rotor. Make sure that the tab

TM05 6805 5212

of the inner ring fits into the notch of the shaft.

14. Fit the lock nut (270) on the rotor and tighten it (E).

Check that the bearings rotate smoothly without any significant play. Adjust if necessary.

15. Bend one tab of the lock washer (271) into the notch of the lock nut (270).

16. Grease the roller bearing (162). Fill only 50 % of the free space of the bearing.

17. Fit the O-ring (109) into to the groove of the lower bearing (155).

18. Fill the bottom of the lower bearing bracket cover (59) with grease and fit it on the rotor with screws (182a).

19. Lift the upper bearing bracket cover (60) up against the lower bearing bracket (155) using boards. Fit the screws (182b) and tighten so that the components are pulled together.

Make an electrical test of sensors attached to lower bearing bracket.

English (GB)

Angular contact ball bearings might need to be cut in two to remove them.

15. Remove the upper bearing bracket cover (60).

Page 26

9.7.2 Fitting the rotor

Caution

Note

Caution

Note

Stationary part of the secondary shaft seal

Assembly tool PUR131

Assembly tool PUR127

O-ring

English (GB)

1. Lift up the rotor with a hoist and fit O-ring (72).

2. Lower the rotor/shaft into the stator housing (55), leaving approximately 10 cm open. Secure rotor/stator with boards between stator housing (55) and lower bearing bracket (155).

3. Connect the sensor connecting block.

4. Remove the boards and complete the fitting of the rotor/shaft. Pull protection sensor wires tight as the rotor is lowered down.

5. Fit the screws (184a).

Older models only have two bolts between stator housing and lower bearing bracket. In these models, secure the assembly of the two components with four pairs of bolts and nuts.

9.7.3 Fitting the upper bearing

1. Place the motor in vertical position (shaft downwards) on for instance a stable trestle.

2. Grease the upper bearing (154). Fill only 50 % of the free space of the bearing. See section 6.3 Quantities of grease in bearings.

3. Heat the bearing housing (61) up to 120 °C. Fit the upper bearing (154) in the bearing housing (61).

4. Fit the circlip (61b) in the bearing housing (C).

5. Heat bearing housing and bearing up to 120 °C and fit them on the shaft.

Let the bearing housing and bearing cool down before continuing.

6. Fit and lubricate the O-rings (61a).

7. Fill up the bearing with grease.

9.7.4 Fitting the terminal box

1. Fit and lubricate the O-ring (756).

2. Fit the terminal box (164a) including the intermediate ring (755) on the stator housing (55). Guide the cables out of the stator side of the terminal box.

3. Fit the screws (178a)

If the intermediate ring is not included on the pump, fit the terminal box to stator housing with screws (178).

4. Connect the protection sensor cables to terminal block according to the wiring diagram. See section 11 .6 Electrical

connections.

5. Fit the stator cables to the terminal board (177) with spring washers and nuts. Tighten the nuts with a torque of 40 Nm. Connect according to the wiring diagrams. See section 11.6 Electrical connections.

9.7.5 Fitting the secondary shaft seal

TM05 6175 4512

Fig. 33 Fitting the stationary part of the secondary shaft seal,

range 74

1. Place the motor in horizontal position on for instance a stable trestle.

2. Make sure that the shaft is clean and smooth.

3. Fit and lubricate the O-ring on the stationary part of the secondary shaft seal (105b).

4. Fit the stationary part of the secondary shaft seal (105b) and press it home (P and T). See fig. 33.

Make sure that the pin in lower bearing bracket cover (59) fits into the notch of the stationary part.

Test the electrical circuits.

6. Fit the moisture absorbing bag (760) in the terminal box (164a).

The terminal box must be closed within one hour after the new moisture absorbing bag has been exposed to atmospheric humidity.

7. Lubricate and fit the O-ring (165) to the terminal box cover (164).

8. Fit the terminal box cover (164) on the terminal box (164a) with screws (166).

Page 27

9.7.7 Fitting the primary shaft seal

Note

41 ± 0.5

46.8 ± 0.5

Rotating part of the secondary shaft seal

Assembly tool PUR131

Assembly tool PUR127

Screws, tightening torque 8 Nm

O-ring

Note

Stationary part of primary shaft seal

Assembly tool PUR128

Assembly tool PUR127

O-ring

Rotating part of primary shaft seal

Assembly tool PUR127

Screws, tightening

torque 15 Nm

63.2 ± 0.5 69 ± 0.5

O-ring

English (GB)

Fig. 34 Fitting the rotating part of secondary shaft seal, range

5. Check that an O-ring is fitted inside the rotating part of secondary shaft seal (105b).

6. Lubricate sliding surfaces with silicone spray.

7. Fit the rotating part of the secondary shaft seal on the shaft and press it home (P and T). Tighten the set screws in the secondary shaft seal (105b) with a torque of 8 Nm. See fig.

34.

8. Check the assembly length (46.8 mm ± 0.5 mm) of the secondary shaft seal (L).

Check the possible leak paths with leak detecting liquid between stator housing and lower bearing bracket. See section 10.1 Tightness test of stator (submerged).

Tightness of complete motor must be verified through a submersion test.

9.7.6 Fitting the shaft seal housing

1. Lubricate and fit the O-ring (72a).

2. Fit the O-ring (37c) to shaft seal housing (58).

3. Fit the shaft seal housing (58) using a hoist.

4. Fit the screws (184).

TM05 6176 4512

Fig. 35 Fitting the stationary part of primary shaft seal, range

1. Make sure that the shaft is clean and smooth.

2. Lubricate and fit the O-ring on the stationary part of the primary shaft seal (105). Fit the shaft seal on the shaft and press it home (P and Q). See fig. 35.

Make sure that the pin in shaft seal housing (58) fits into the notch of the stationary part.

TM05 6177 4512

TM05 6178 4512

Fig. 36 Fitting the rotating part of primary shaft seal, range 74

3. Check that an O-ring is fitted inside the rotating part of primary shaft seal (105). Lubricate the O-ring.

4. Lubricate the sliding surfaces with silicone spray.

5. Fit the rotating part of the primary shaft seal on the shaft and press it home (P). See fig. 36. Tighten the set screws in the shaft seal with a torque of 15 Nm.

6. Check the assembly length (69 mm ± 0.5 mm) of the secondary shaft seal (L).

Check the possible leak paths with leak detecting liquid. See section 10.1.1 Tightness test of shaft seal housing (submerged).

Tightness of complete motor must be verified through a submersion test.

Page 28

9.7.8 Fitting the cooling jacket

Note

English (GB)

This section applies only to pumps with cooling jacket.

1. Place the motor in vertical position (shaft downwards) on for instance a stable trestle.

2. Lubricate and fit the O-ring (37a).

3. Fit the cooling jacket (150c) with a hoist.

4. Lubricate and fit the O-ring (157b).

5. Fit the locking ring (754).

6. Fit the screws (150a).

9.7.9 Fitting the motor top cover and connections in the

terminal box

1. Place the motor in horizontal position on for instance a stable trestle.

Steps 2 to 5 apply only to pumps without adapter flange.

2. Fit the O-ring (157a).

3. Support the motor top cover (151) with a lifting strap and hoist.

4. Fit the motor top cover (151) on the terminal box (164a).

5. Fit the screws (183).

Steps 6 to 12 apply only to pumps with adapter flange.

6. Secure the motor top cover (151) with hoist.

7. Fit the O-ring (157a).

8. Fit motor top cover (151) to terminal box (164a).

9. Fit screws (183).

10. Lubricate and fit O-ring (39c).

11. Support cable assembly with a lifting strap and fit to motor top cover.

12. Fit screws (183b).

13. Fit the lifting bracket (190).

14. Fit the screws (190b).

15. Connect the earth conductors of the power cables (181) to the terminal box (164a). Fit locking plate (11) and hexagon head screws (10) on the cable shoes. Secure connection by bending one corner of locking plate (11) up towards the screw (10).

16. Connect the power cable wires to the terminal board (177) according to the wiring diagram. Fit the spring washers and screws. Tighten the screw with a torque of 20 Nm. See section

11.6 Electrical connections.

17. Fit the terminal block including bracket in the terminal box (164a) with spring washers and screws.

18. Connect the protection sensor cables on the terminal block.

9.7.10 Oil filling

1. See section 8.4 Oil check and oil change.

9.7.11 Fitting the impeller and the pump housing

1. Place the motor in horizontal position on for instance a stable trestle.

2. Make sure that the O-ring is fitted on the primary shaft seal.

3. Fit the key (9a) in the shaft groove (D).

4. Lubricate the cone of the shaft and the O-ring of the primary shaft seal.

5. Secure impeller (49) with a lifting strap and hoist.

6. Fit the impeller (49).

7. Fit the O-ring (62a) on the cap (66).

8. Fit the O-ring (67b) on the impeller screw (67).

9. Lightly lubricate the O-rings (62a and 67b) and the thread of the impeller screw (67).

10. Fit the cap (66) and the impeller screw (67).

11. Support the impeller (49) with a board and tighten the impeller screw (67) with a torque of 600 Nm. Before final tightening of the impeller screw, knock the impeller (D) to make sure it is on correct position.

12. Bend (B and D) the edge of the cap (66) into the notch of the impeller screw (67).

The new impeller may be higher than the old impeller, so open the impeller clearance before assembling the pump housing.

13. Fit and lubricate the O-ring (37b).

14. Support the pump housing (50) beneath the discharge flange with wedges.

15. Place the motor in vertical position with a hoist and mount the motor on the pump housing (50).

16. Fit the screws (26).

9.7.12 Adjusting the impeller clearance

17. Check and adjust the impeller clearance. See section

8.5 Inspection and adjustment of impeller clearance.

Test the electrical circuits.

19. Fit the O-ring (165) to the terminal box cover (164).

20. Fit the terminal box cover (164) on the terminal box (164a) with screws (166).

Check the possible leak paths through tightness test of terminal box (cable side).

See section 10.2 Tightness test of terminal box (cable side, submerged).

Tightness of complete motor must be verified through a submersion test.

The submersion test must be made before oil filling.

Page 29

9.8 Dismantling range 78

Note

For position numbers, see section 11.3 Range 78.

Warning Maintenance and service work on explosion

proof pumps must be carried out by Grundfos or a service workshop authorised by Grundfos.

Warning When lifting range 78 pumps by the shaft, you

must use special lifting tool (DD). See section

7.4 Lifting tools.

9.8.1 Removing the impeller and the pump housing

Before dismantling, support the pump unit from the lifting bracket with a hoist and beneath the discharge flange with wedges.

1. Remove the outer screws (26).

2. Lift the pump including the impeller (49) out of the pump housing (50) with a hoist. Use wedges, if necessary.

3. Place the motor with impeller in horizontal position on for instance a stable trestle.

4. Remove the O-ring (37b).

5. Support the impeller with the lifting strap, board and hoist to prevent movement.

6. Remove the impeller screw (67a) including O-ring (67b) and cap (66) including O-ring (62a).

7. Loosen the three impeller screws (67), but do not remove the screws yet.

8. Loosen the impeller (49), use wedges if necessary.

9. Remove the impeller screws (67) and locking plate (66a).

10. Remove the impeller (49).

11. Remove the key (9a).

9.8.2 Draining the Oil

1. See section 8.4 Oil check and oil change.

9.8.3 Removing the primary shaft seal

1. See section 9.6.3 Removing the p rimary seal .

9.8.4 Removing the motor top cover

1. See section 9.6.4 Removing the motor top cover.

9.8.5 Removing the cooling jacket

1. See section 9.6.5 Removing the cooling jacket

9.8.6 Removing the terminal box

1. See section 9.6.6 Removing the terminal box.

9.8.7 Removing the upper bearing bracket

1. Remove screws (753).

2. Remove the upper bearing bracket (61c) from the stator housing (55) by driving the screws against the end of the rotor shaft. Use screws M20 x 140 DIN933.

3. Lift off the upper bearing bracket (61c).

9.8.8 Removing the upper bearing

1. See section 9.6.7 Removing the upper bearing.

9.8.9 Removing the shaft seal housing

1. See section 9.6.8 Removing the shaft seal housing.

9.8.10 Removing the secondary shaft seal

1. See section 9.6.9 Removing the secondary shaft seal.

9.8.11 Removing the rotor

1. See section 9.6.10 Removing the rotor.

9.8.12 Removing th e low er be arin gs

English (GB)

TM05 6808 5212

Fig. 37 Rotor and lower bearings, range 78

1. Remove the screws (182b). See fig. 37.

2. Remove the upper bearing bracket cover (60) and leave it on the stator windings.

3. Remove the screws (182a).

4. Remove the lower bearing bracket cover (59).

5. Remove the O-ring (109).

6. Remove the lock nut (270), lock washer (271) and angle ring (269).

7. Remove the lower bearing bracket (155) with the hoist and remove O-ring (72a).

The outer ring of the roller bearing and the rolls will be removed together with the bearing bracket.

8. Collect the springs (153a).

9. Gently heat up the roller race and pull off the bearing (162) and supporting ring (197).

10. Heat up the locking ring (59a) to 200 °C and pull it off.

11. Remove the angular contact ball bearings (153) from the shaft.

Angular contact ball bearings might need to be cut in two to remove them.

Step 12 applies only to pumps that have a labyrinth seal.

12. Gently heat up the labyrinth seal (60a) and pull it off.

13. Remove the upper bearing bracket cover (60).

Page 30

9.9 Assembling range 78

Note

Stationary part of the shaft seal

Assembly tool PUR132

Assembly tool PUR129

Screws M16 x 70 (three)

O-ring

Note

Assembly tool PUR129

Assembly tool PUR132

Set screws (five). Tightening torque: 15 Nm

Rotating part of shaft

seal

52.5 ± 0.5

55.2 ± 0.5

O-ring

English (GB)

9.9.1 Fitting the lower bearings

1. See section 9.7.1 Fitting the lower bearings.

9.9.2 Fitting the rotor

1. See section 9.7.2 Fitting the rotor.

9.9.3 Fitting the upper bearing

1. See section 9.7.3 Fitting the upper bearing.

9.9.4 Fitting the upper bearing bracket

1. Lower the upper bearing bracket (61c) into the stator housing (55), leaving a space of approximately 20 cm.

2. Pull the cables gently through the holes in the upper bearing bracket. Complete the fitting of the bracket on the stator.

3. Fit the screws (753).

9.9.5 Fitting the terminal box

1. See section 9.7.4 Fitting the terminal box.

9.9.6 Fitting the secondary shaft seal

TM05 6266 4512

Fig. 39 Fitting the rotating part of the secondary shaft seal,

range 78

5. Check that an O-ring is fitted inside the rotating part of secondary shaft seal (105b).

6. Lubricate sliding surfaces with silicone spray.

7. Fit the rotating part of the secondary shaft seal on the shaft and press it home (R and U). Tighten the set screws in the secondary shaft seal (105b) with a torque of 15 Nm. See fig.

39.

8. Check the assembly length (55.2 ± 0.5 mm) of the secondary shaft seal (L).

Fig. 38 Fitting the stationary part of the secondary shaft seal,

range 78

1. Place the motor in horizontal position on for instance a stable trestle.

2. Make sure that the shaft is clean and smooth.

3. Lubricate and fit the O-ring on the stationary part of the secondary shaft seal (105b).

4. Fit the stationary part of the secondary shaft seal (105b) and press it home (R and U). See fig. 38.

Make sure that the pin in lower bearing bracket cover (59) fits into the notch of the stationary part.

Check the possible leak paths with leak detecting liquid between stator housing and lower bearing bracket.

See section 10.1 Tightness test of stator (submerged).

TM05 6265 4512

Tightness of complete motor must be verified through a submersion test.

9.9.7 Fitting the shaft seal housing

1. See section 9.7.6 Fitting the shaft seal housing.

Page 31

9.9.8 Fitting the primary shaft seal

Note

Assembly tool PUR129

Assembly tool PUR130

Stationary part of the shaft seal

Screws M16 x 70 (three)

O-ring

Set screws (five). Tightening torque: 15 Nm.

Assembly tool PUR129

Rotating part of

shaft seal

70 ± 0.5

74 ± 0.5

O-ring

Note

Fig. 40 Fitting the stationary part of primary shaft seal, range

1. Make sure that the shaft is clean and smooth.

2. Lubricate and fit the O-ring on the stationary part of the primary shaft seal (105). Fit the shaft seal on the shaft and press it home (R and S). See fig. 40.

9.9.9 Fitting the cooling jacket

1. See section 9.7.8 Fitting the cooling jacket.

2. Fitting the motor top cover and the connections of the terminal box

1. See section 9.7.9 Fitting the motor top cover and connections in the terminal box.

9.9.10 Oil filling

1. See section 8.4 Oil check and oil change.

9.9.11 Fitting the impeller and the pump housing

1. Check that the O-ring is fitted on the primary shaft seal (105).

2. Fit the key (9a) in the shaft groove (D).

3. Lightly lubricate the cone of the shaft and O-ring of the primary shaft seal.

4. Secure the impeller with lifting strap and hoist.

5. Fit the impeller (49) and support it with a board.

TM05 6267 4512TM05 6268 4512

6. Fit the locking plate (66a) and three impeller screws (67). Tighten the screws with a torque of 170 Nm. Before final tightening of the impeller screws (67) knock the impeller (D) to make sure it is in correct position.

7. Fit the O-ring (62a) on the cap (66)

8. Fit O-ring (67b) on the screw (67a). Lightly lubricate the thread, screw head and the O-ring (67b).

9. Fit the cap (66). Make sure that the pin of the cap fits into the notch of the locking plate (66a).

10. Fit the screw (67a) and tighten to a torque of 160 Nm.

English (GB)

Fig. 41 Fitting the rotating part of primary shaft seal in range

78 pumps.

3. Check that the O-ring is fitted inside the rotating part of primary shaft seal (105). Lubricate the O-ring.

4. Fit the rotating part of the primary shaft seal on the shaft and press it home (R). Tighten the set screws in the shaft seal with a torque of 15 Nm. See fig. 41.

5. Check the assembly length (74 ± 0.5 mm) of the primary shaft seal (L).

Check the possible leak paths with leak detecting liquid.

See section 10.1.1 Tightness test of shaft seal housing (submerged).

Tightness of complete motor must be verified through a submersion test.

The new impeller may be higher than the old impeller, so open the impeller clearance before assembling the pump housing.

11. Lubricate and fit the O-ring (37b).

12. Support the pump housing (50) beneath the discharge flange with wedges.

13. Lift the motor into vertical position with a hoist and mount the motor on the pump housing (50).

14. Fit the screws (26).

9.9.12 Adjusting the impeller clearance

1. Check and adjust the impeller clearance. See section

8.5 Inspection and adjustment of impeller clearance.

Page 32

10. Tightness tests

Note

English (GB)

10.1 Tightness test of stator (submerged)

Warning Maintenance and service work on explosion

proof pumps must be carried out by Grundfos or a service workshop authorised by Grundfos.

Fig. 42 Test plugs in shaft seal housing and lower bearing

bracket

1. Place the motor in horizontal position with a hoist.

2. Remove the upper oil plug (193) including O-ring (194) from

the shaft seal housing. See fig. 42.

3. Fit the test plug (Connector R3/4) in stead of the oil plug (193).

4. Fit the hose (approx. 1 m) to the test plug.

Step 5 applies only to Ex pumps.

5. Remove the screw (25a) from the lower bearing bracket.

6. Remove the plug (25) including O-ring (100) from the lower bearing bracket (155).

7. Fit the test plug (3/8-24 UNF F-ISO 228-G 3/8M) in stead of the plug (25).

8. Fit the gas hose (N2) to the test plug and pressurise the stator housing to 0.8 bar.

9. Submerge the motor into the test basin.

10. Place the end of the hose coming from the shaft seal housing under the surface of the water.

In order to detect possible leaks, let the motor stay submerged for 15 minutes.

11. Lift the motor out of the test basin.

12. Disconnect the gas hoses and the test plugs.

13. Fit the plug (25) including O-ring (100) on the lower bearing bracket.

Warning In explosion proof pumps, the plug (25) on the

shaft seal housing must be locked with a screw (25a).

14. Fit the upper oil plug (193) including O-ring (194) to the shaft seal housing.

10.1.1 Tightness test of shaft seal housing (submerged)

1. Place the motor in horizontal position with a hoist.

2. Remove the oil plug (193) including O-ring (194) from the shaft seal housing.

3. Fit the test plug (R3/4) in stead of the oil plug (193). See fig.

42.

4. Fit the gas hose (N2) to the test plug and pressurise the shaft seal housing to 0.8 bar.

5. Submerge the motor into the test basin.

In order to detect possible leaks, let the motor stay submerged for 15 minutes.

6. Lift the motor out of the test basin.

7. Disconnect the gas hose and the test plug.

8. Fit the oil plug (193) including O-ring (194) on the shaft seal housing.

10.2 Tightness test of terminal box (cable side, submerged)

Warnin g Maintenance and service work on explosion

proof pumps must be carried out by Grundfos or a service workshop authorised by Grundfos.

TM05 6810 5212

TM05 6809 5212

Fig. 43 Test plugs in terminal box

Step 1 applies only to Ex pumps.

1. Remove the screw (25a) from the terminal box (164a).

See fig. 43.

2. Remove the plug (25) including O-ring (100) from the terminal

box.

3. Fit the test plug (connector 3/8-24 UNF F-ISO 228-G 3/8M) in

stead of plug (25).

4. Fit the gas hose (N2/dry pressurised air) to the test plug and

pressurise the stator housing to 0.8 bar.

5. Submerge the motor into the test basin.

In order to detect possible leaks, let the motor stay submerged for 15 minutes.

6. Lift the motor out of the test basin.

7. Disconnect the gas hose and the test plug.

8. Fit the plug (25) including O-ring (100) on the terminal box.

Warnin g In explosion proof pumps, the plug (25) on the

terminal box must be locked with a screw (25a).

Page 33

11. Drawings

Please note that the position numbers in the drawings in sections

11.1 to 11.3 are listed in section 11.4 Position numbers an d

material specification.

11.1 Range 72

Exploded view, installation type S

English (GB)

TM03 3055 0508

Page 34

Sectional drawing, installation type S

English (GB)

TM03 3615 0508

Page 35

Exploded view, installation type C

English (GB)

TM03 3054 0508

Page 36

Sectional drawing, installation type C

English (GB)

TM03 3425 0508

Page 37

Exploded view, installation type D

English (GB)

TM03 3053 0508

Page 38

Sectional drawing, installation type D

English (GB)

TM03 3423 0508

Page 39

Installation type S with cooling jacket

English (GB)

TM05 8604 2513

Page 40

Installation type S without cooling jacket

English (GB)

TM05 8603 2513

Page 41

Column pipe installation

English (GB)

TM05 8605 2513

Page 42

11.2 Range 74

English (GB)

Sectional drawing, installation type C (with intermediate ring)

TM05 8595 2513

Page 43

Sectional drawing, column pipe installation 315* (without cooling jacket)

* Based on IEC 315 motor series parts.

English (GB)

TM05 8594 2513

Page 44

Submerged installation (old and new guide claw)

Old guide claw

English (GB)

TM05 8620 2513

Page 45

Dry, vertical installation

English (GB)

TM05 8596 2513

Page 46

Dry, horizontal installation

English (GB)

TM05 8597 2513

Page 47

Column pipe installation

English (GB)

TM05 8598 2513

Page 48

11.3 Range 78

English (GB)

Installation type C with cooling jacket (manufactured between 1992 and 1996)

TM06 0379 0101

Page 49

Installation type C with cooling jacket

English (GB)

TM05 8599 2513

Page 50

Column pipe installation

English (GB)

TM05 8600 2513

Page 51

Installation type C with (old and new) guide claw

Old guide claw

English (GB)

TM05 8621 2513

Page 52

Installation type D (vertical installation with concrete base)

English (GB)

TM05 8619 2513

Page 53

Installation type H (horizontal installation)

English (GB)

TM05 8601 2513

Page 54

Installation type ST (column pipe installation)

English (GB)

TM05 8602 2513

Page 55

Installation type SA (column pipe installation, propeller)

English (GB)

TM06 0378 0101

Page 56

11.4 Position numbers and material specification

English (GB)

Motor

Pos. Component Material

7a Rivet Stainless steel 25 Pressure test plug Stainless steel 25a Screw Stainless steel 26a Screw Stainless steel 26b Screw Stainless steel 37a O-ring NBR rubber 37c O-ring NBR rubber 39c O-ring NBR rubber 48 Stator windings 55 Stator housing Cast iron 58 Shaft seal housing Cast iron 59 Lower bearing bracket cover Cast iron 59a Locking ring Aluminium 59b Pin Steel 60 Upper bearing bracket cover Cast iron 60a Labyrinth seal 61 Bearing housing Cast iron 61a O-ring Viton rubber 61b Circlip Steel 61c Upper bearing bracket Cast iron 72 O-ring NBR rubber 72a O-ring NBR rubber 76a Approval plate Stainless steel 76b Warning plate Stainless steel 77 Seal housing cover Cast iron 100 O-ring NBR rubber 101c Locking pin Stainless steel 101d Screw Stainless steel 105 Mechanical shaft seal SiC/SiC, stainless steel

105b Mechanical shaft seal

107 O-ring NBR rubber 109 O-ring Viton rubber 150a Screw Stainless steel 150c Cooling jacket Galvanized steel 151 Motor top cover Cast iron 153 Angular contact ball bearing Steel, brass or steel cage 153a Spring Steel 154 Ball bearing Steel, brass or steel cage 155 Lower bearing bracket Cast iron 157 O-ring NBR rubber 157a O-ring NBR rubber 157b O-ring NBR rubber 162 Roller bearing Steel, brass or steel cage 164 Terminal box cover Cast iron 164a Motor top cover / terminal box Cast iron 165 O-ring NBR rubber 166 Screw Stainless steel 168 Cable entry Cast iron 168a Adapter flange Stainless steel 172 Shaft with rotor Tempered steel 173 Screw Steel 173b Locking plate Steel 173c Washer Steel 173e Screw Stainless steel 173f Spring washer Stainless steel 173g Earth connector Steel 176 Connector set 176a Terminal block 176b Screw Stainless steel

SiC/carbon, stainless steel

Pos. Com po nent Material

176c Terminal block 176d Screw Steel 177 Terminal board 177a Protection sleeve Rubber or plastic 178 Screw Stainless steel 178a Screw Stainless steel 180 Cable clamp Cast iron 180a Screw Stainless steel 181 Cable Copper, EPR-insulated 181a Screw Stainless steel 182a Screw Stainless steel 182b Screw Stainless steel 183 Screw Stainless steel 184 Screw Stainless steel 184a Screw Stainless steel 190 Lifting bracket Galvanized steel 190a Lifting bracket Galvanized steel 190b Screw Stainless steel 190c Screw Stainless steel 193 Plug Stainless steel 194 O-ring NBR rubber 197 Supporting ring Steel 198 Rubber seal Neoprene rubber 248 Screw Stainless steel 248a Screw Stainless steel 250 Cable clamp Cast iron 250a Cable entry Cast iron 250b Rubber seal Neoprene rubber 252 Cable Copper, EPR-insulated 269 Angle ring Steel 270 Lock nut Steel 271 Lock Washer Steel 272 Vent pipe 519 Conductor bushing 520d Protection sensors 521 Water-in-oil sensor (WIO) 522a Screw Steel 522b Washer Steel 522d Pipe retaining clips Steel 523 Cable gland Steel / rubber 523a O-ring NBR rubber 524a Bracket for SM113 Aluminium 524b Screw Steel 524c Screw Steel 524d Spring washer Steel 529 SM 113 753 Screw Steel 754 Locking ring Cast iron 755 Intermediate ring Cast iron 756 O-ring NBR rubber 759 Protection ring Aluminium 760 Moisture absorbing bag Zeolite absorbent

Page 57

Pump

Pos. Component Material

1 Intermediate ring Cast iron 7a Rivet Stainless steel 9a Key (for keyway) Steel 12 Flange Cast iron 12a Suction cover Cast iron 12c Set screw Stainless steel 26 Screw Stainless steel 26c Screw Stainless steel 35 Screw Stainless steel 35a Screw Stainless steel 37 O-ring NBR rubber 37b O-ring NBR rubber 39 O-ring NBR rubber 39a O-ring NBR rubber *49 Impeller Cast iron *50 Pump housing Cast iron 62 O-ring NBR rubber 62a O-ring NBR rubber 66 Cap Cast iron or stainless steel 66a Locking plate Steel 67 Impeller screw Stainless steel 67a Screw Stainless steel 67b O-ring NBR rubber 67c Parallel pin Steel 76 Nameplate Stainless steel 301 Motor unit 487a Base plate Steel 487c Screw Stainless steel 487d Washer Steel 488 O-ring NBR rubber 492 Guide claw Cast iron 492a Rubber seal Neoprene rubber 493 Screw Stainless steel 494 Plug Stainless steel 495 O-ring NBR rubber 762a Screw Stainless steel 762b Flange seal

* Available of stainless steel (custom-built option).

English (GB)

Page 58

11.5 Sensor positions

English (GB)

Please note that the position numbers in section 11.5 refer exclusively to the sensors.

Range 74 and 78 manufactured between 1992 to 2012

Pos. Description

1 Pt100 sensor 2 Plug strip (male) 3 Socket strip (female) 4 Cylinder screw 5 Rubber plate 6 Moisture switch 7 Cylinder screw 8 Bracket

9 Cylinder screw 10 Lock washer 11 Insulated conducting wire 12 Silicone rubber sleeve

TM05 8682 2613

Page 59

Range 74 and 78, current models

English (GB)

Pos. Description Pos. Description

1 Pt100 (temperature) sensor 12 Bracket

2 Pt100 (temperature) sensor insulated 13 Cylinder screw

3 Plug strip (male) 14 Lock washer

4 Socket strip (female) 15 Insulated conducting wire

5 Cylinder screw 16 Screen

6 WIO sensor 17 Silicone rubber sleeve

7 O-ring 18 Insulation ring

8 Cable gland 19 Sensor bracket (WIO)

9 Moisture switch 20 Hexagon head screw 10 Connector (female) 21 Spring washer 11 Cylinder screw

Option

Pos. Description

22 Vibration sensor 23 Hexagon head screw 24 Lock washer

TM05 8680 2613

Page 60

11.6 Electrical connections

T777

P222

3P3

T44T4

11 P1

P2 P1P3

W2 V2

W1 V1

T4 T4

8P8

Terminal box Motor

Free end of

4-conductor

cable

Free end of

9-conductor

cable

Moisture switches

Angular contact bearings

Ball bearing

Roller bearing

U1 U1

U2 U2

V1 V1

V2 V2

W1 W1

W2 W2

22 2 2

8888

T1T2

% H2O

4-20 mA

Terminal box

Motor

WIO sensor

Upper bearing

Lower bearing Stator

Moisture switches

Green/Yellow

Grey

Brown

Black

Free end of

10-conductor

cable

English (GB)

Warning The following wiring diagrams are examples for standard pump models and they are not suitable for all pumps. Wrong electrical connections may cause injury to personnel or damage to the pump. To make sure the wiring diagrams are suitable for the pump, contact Grundfos or an authorised service workshop.

Wiring diagram for pumps manufactured before 2009

Wiring diagram for pumps manufactured in 2009 and later

TM06 0371 5313

TM06 0353 5113

Page 61

Wiring diagrams for EMC pumps

989

777

666

333

4-20 mA

% H O

W2W1W2

V2V2

V1U2V1

V1 V2

U1U1

U1 U2

16 17

14 14

7 8

1 2

3 3

U1V1W1

U2V2W2

Motor

Terminal box

Free end of

3-conductor

cable

Free end of

18-conductor

cable

Lower bearing Stator

Upper bearing

WIO sensor

Moisture switches

55555

17 7

% H O

4-20 mA

1212

W2W2

W1W1

V2V2

V1V1

U2U1U2

V1 V2

U1 U2

U1W1

U2W2

MotorTerminal box

Free end of

18-conductor

cable

Lower bearing Stator

Upper bearing

WIO sensor

Moisture switches

Free end of 3-conductor cable

English (GB)

TM06 0373 5313

TM06 0374 5313

Page 62

Wiring diagram for Ex pumps

U1 U1

W2W2

V2V2

V1 V2

U1 U2

88 T4

Motor

Terminal box

Free end of 3-conductor cable

Free end of

18-conductor

cable

Ball bearing Angular contact bearings

Roller bearing Winding

Moisture switches

English (GB)

Warning The control circuits are intrinsically safe circuits (see EN 50014 and EN 50020), and in the control panel they must be

connected to an associated apparatus approved for EEx ia IIB circuits (typically safety barriers).

TM06 0372 5313

Page 63

Argentina

Bombas GRUNDFOS de Argentina S.A. Ruta Panamericana km. 37.500 Centro Industrial Garin 1619 Garín Pcia. de B.A. Phone: +54-3327 414 444 Telefax: +54-3327 45 3190

Australia

GRUNDFOS Pumps Pty. Ltd. P.O. Box 2040 Regency Park South Australia 5942 Phone: +61-8-8461-4611 Telefax: +61-8-8340 0155

Austria

GRUNDFOS Pumpen Vertrieb Ges.m.b.H. Grundfosstraße 2 A-5082 Grödig/Salzburg Tel.: +43-6246-883-0 Telefax: +43-6246-883-30

Belgium

N.V. GRUNDFOS Bellux S.A. Boomsesteenweg 81-83 B-2630 Aartselaar Tél.: +32-3-870 7300 Télécopie: +32-3-870 7301

Belarus

Представительство ГРУНДФОС в Минске 220125, Минск ул. Шафарнянская, 11, оф. 56, БЦ «Порт» Тел.: +7 (375 17) 286 39 72/73 Факс: +7 (375 17) 286 39 71

E-mail: minsk@grundfos.com

Bosna and Herzegovina

GRUNDFOS Sarajevo Zmaja od Bosne 7-7A, BH-71000 Sarajevo Phone: +387 33 592 480 Telefax: +387 33 590 465 www.ba.grundfos.com e-mail: grundfos@bih.net.ba

Brazil

BOMBAS GRUNDFOS DO BRASIL Av. Humberto de Alencar Castelo Branco, 630 CEP 09850 - 300 São Bernardo do Campo - SP Phone: +55-11 4393 5533 Telefax: +55-11 4343 5015

Bulgaria

Grundfos Bulgaria EOOD Slatina District Iztochna Tangenta street no. 100 BG - 1592 Sofia Tel. +359 2 49 22 200 Fax. +359 2 49 22 201 email: bulgaria@grundfos.bg

Canada

GRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: +1-905 829 9533 Telefax: +1-905 829 9512

China

GRUNDFOS Pumps (Shanghai) Co. Ltd. 50/F Maxdo Center No. 8 XingYi Rd. Hongqiao development Zone Shanghai 200336 PRC Phone: +86 21 612 252 22 Telefax: +86 21 612 253 33

Croatia

GRUNDFOS CROATIA d.o.o. Buzinski prilaz 38, Buzin HR-10010 Zagreb Phone: +385 1 6595 400 Telefax: +385 1 6595 499 www.hr.grundfos.com

Czech Republic

GRUNDFOS s.r.o. Čajkovského 21 779 00 Olomouc Phone: +420-585-716 111 Telefax: +420-585-716 299

Denmark

GRUNDFOS DK A/S Martin Bachs Vej 3 DK-8850 Bjerringbro Tlf.: +45-87 50 50 50 Telefax: +45-87 50 51 51 E-mail: info_GDK@grundfos.com www.grundfos.com/DK

Estonia

GRUNDFOS Pumps Eesti OÜ Peterburi tee 92G 11415 Tallinn Tel: + 372 606 1690 Fax: + 372 606 1691

Finland

OY GRUNDFOS Pumput AB Mestarintie 11 FIN-01730 Vantaa Phone: +358-(0)207 889 900 Telefax: +358-(0)207 889 550

France

Pompes GRUNDFOS Distribution S.A. Parc d’Activités de Chesnes 57, rue de Malacombe F-38290 St. Quentin Fallavier (Lyon) Tél.: +33-4 74 82 15 15 Télécopie: +33-4 74 94 10 51

Germany

GRUNDFOS GMBH Schlüterstr. 33 40699 Erkrath Tel.: +49-(0) 211 929 69-0 Telefax: +49-(0) 211 929 69-3799 e-mail: infoservice@grundfos.de Service in Deutschland: e-mail: kundendienst@grundfos.de

HILGE GmbH & Co. KG Hilgestrasse 37-47 55292 Bodenheim/Rhein Germany Tel.: +49 6135 75-0 Telefax: +49 6135 1737 e-mail: hilge@hilge.de

Greece

GRUNDFOS Hellas A.E.B.E. 20th km. Athinon-Markopoulou Av. P.O. Box 71 GR-19002 Peania Phone: +0030-210-66 83 400 Telefax: +0030-210-66 46 273

Hong Kong

GRUNDFOS Pumps (Hong Kong) Ltd. Unit 1, Ground floor Siu Wai Industrial Centre 29-33 Wing Hong Street & 68 King Lam Street, Cheung Sha Wan Kowloon Phone: +852-27861706 / 27861741 Telefax: +852-27858664

Hungary

GRUNDFOS Hungária Kft. Park u. 8 H-2045 Törökbálint, Phone: +36-23 511 110 Telefax: +36-23 511 111

India

GRUNDFOS Pumps India Private Limited 118 Old Mahabalipuram Road Thoraipakkam Chennai 600 096 Phone: +91-44 2496 6800

Indonesia

PT GRUNDFOS Pompa Jl. Rawa Sumur III, Blok III / CC-1 Kawasan Industri, Pulogadung Jakarta 13930 Phone: +62-21-460 6909 Telefax: +62-21-460 6910 / 460 6901

Ireland

GRUNDFOS (Ireland) Ltd. Unit A, Merrywell Business Park Ballymount Road Lower Dublin 12 Phone: +353-1-4089 800 Telefax: +353-1-4089 830

Italy

GRUNDFOS Pompe Italia S.r.l. Via Gran Sasso 4 I-20060 Truccazzano (Milano) Tel.: +39-02-95838112 Telefax: +39-02-95309290 / 95838461

Japan

GRUNDFOS Pumps K.K. Gotanda Metalion Bldg., 5F, 5-21-15, Higashi-gotanda Shiagawa-ku, Tokyo 141-0022 Japan Phone: +81 35 448 1391 Telefax: +81 35 448 9619

Korea

GRUNDFOS Pumps Korea Ltd. 6th Floor, Aju Building 679-5 Yeoksam-dong, Kangnam-ku, 135-916 Seoul, Korea Phone: +82-2-5317 600 Telefax: +82-2-5633 725

Latvia

SIA GRUNDFOS Pumps Latvia Deglava biznesa centrs Augusta Deglava ielā 60, LV-1035, Rīga, Tālr.: + 371 714 9640, 7 149 641 Fakss: + 371 914 9646

Lithuania

GRUNDFOS Pumps UAB Smolensko g. 6 LT-03201 Vilnius Tel: + 370 52 395 430 Fax: + 370 52 395 431

Malaysia

GRUNDFOS Pumps Sdn. Bhd. 7 Jalan Peguam U1/25 Glenmarie Industrial Park 40150 Shah Alam Selangor Phone: +60-3-5569 2922 Telefax: +60-3-5569 2866

Mexico

Bombas GRUNDFOS de México S.A. de C.V. Boulevard TLC No. 15 Parque Industrial Stiva Aeropuerto Apodaca, N.L. 66600 Phone: +52-81-8144 4000 Telefax: +52-81-8144 4010

Netherlands

GRUNDFOS Netherlands Velu we zoom 3 5 1326 AE Almere Postbus 22015 1302 CA ALMERE Tel.: +31-88-478 6336 Telefax: +31-88-478 6332 E-mail: info_gnl@grundfos.com

New Zealand

GRUNDFOS Pumps NZ Ltd. 17 Beatrice Tinsley Crescent North Harbour Industrial Estate Albany, Auckland Phone: +64-9-415 3240 Telefax: +64-9-415 3250

Norway

GRUNDFOS Pumper A/S Strømsveien 344 Postboks 235, Leirdal N-1011 Oslo Tlf.: +47-22 90 47 00 Telefax: +47-22 32 21 50

Poland

GRUNDFOS Pompy Sp. z o.o. ul. Klonowa 23 Baranowo k. Poznania PL-62-081 Przeźmierowo Tel: (+48-61) 650 13 00 Fax: (+48-61) 650 13 50

Portugal

Bombas GRUNDFOS Portugal, S.A. Rua Calvet de Magalhães, 241 Apartado 1079 P-2770-153 Paço de Arcos Tel.: +351-21-440 76 00 Telefax: +351-21-440 76 90

Romania

GRUNDFOS Pompe România SRL Bd. Biruintei, nr 103 Pantelimon county Ilfov Phone: +40 21 200 4100 Telefax: +40 21 200 4101 E-mail: romania@grundfos.ro

Russia

ООО Грундф ос Россия 109544, г. Москва, ул. Школьная, 39-41,

стр. 1 Тел. (+7) 495 564-88-00 (495) 737-30-00 Факс (+7) 495 564 88 11

E-mail grundfos.moscow@grundfos.com

Serbia

Grundfos Srbija d.o.o. Omladinskih brigada 90b 11070 Novi Beograd Phone: +381 11 2258 740 Telefax: +381 11 2281 769 www.rs.grundfos.com

Singapore

GRUNDFOS (Singapore) Pte. Ltd. 25 Jalan Tukang Singapore 619264 Phone: +65-6681 9688 Telefax: +65-6681 9689

Slovenia

GRUNDFOS d.o.o. Šlandrova 8b, SI-1231 Ljubljana-Črnuče Phone: +386 31 718 808 Telefax: +386 (0)1 5680 619 E-mail: slovenia@grundfos.si

South Africa

GRUNDFOS (PTY) LTD Corner Mountjoy and George Allen Roads Wilbart Ext. 2 Bedfordview 2008 Phone: (+27) 11 579 4800 Fax: (+27) 11 455 6066 E-mail: lsmart@grundfos.com

Spain

Bombas GRUNDFOS España S.A. Camino de la Fuentecilla, s/n E-28110 Algete (Madrid) Tel.: +34-91-848 8800 Telefax: +34-91-628 0465

Sweden

GRUNDFOS AB Box 333 (Lunnagårdsgatan 6) 431 24 Mölndal Tel.: +46 31 332 23 000 Telefax: +46 31 331 94 60

Switzerland

GRUNDFOS Pumpen AG Bruggacherstrasse 10 CH-8117 Fällanden/ZH Tel.: +41-44-806 8111 Telefax: +41-44-806 8115

Taiwan

GRUNDFOS Pumps (Taiwan) Ltd. 7 Floor, 219 Min-Chuan Road Taichung, Taiwan, R.O.C. Phone: +886-4-2305 0868 Telefax: +886-4-2305 0878

Thailand

GRUNDFOS (Thailand) Ltd. 92 Chaloem Phrakiat Rama 9 Road, Dokmai, Pravej, Bangkok 10250 Phone: +66-2-725 8999 Telefax: +66-2-725 8998

Turkey

GRUNDFOS POMPA San. ve Tic. Ltd. Sti. Gebze Organize Sanayi Bölgesi Ihsan dede Caddesi,

2. yol 200. Sokak No. 204 41490 Gebze/ Kocaeli Phone: +90 - 262-679 7979 Telefax: +90 - 262-679 7905 E-mail: satis@grundfos.com

Ukraine

Бізнес Центр Європа Столичне шосе, 103 м. Київ, 03131, Україна Телефон: (+38 044) 237 04 00 Факс.: (+38 044) 237 04 01

E-mail: ukraine@grundfos.com

United Arab Emirates

GRUNDFOS Gulf Distribution P.O. Box 16768 Jebel Ali Free Zone Dubai Phone: +971 4 8815 166 Telefax: +971 4 8815 136

United Kingdom

GRUNDFOS Pumps Ltd. Grovebury Road Leighton Buzzard/Beds. LU7 4TL Phone: +44-1525-850000 Telefax: +44-1525-850011

U.S.A.

GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe, Kansas 66061 Phone: +1-913-227-3400 Telefax: +1-913-227-3500

Uzbekistan

Grundfos Tashkent, Uzbekistan The Representative Office of Grundfos Kazakhstan in Uzbekistan 38a, Oybek street, Tashkent Телефон: (+998) 71 150 3290 / 71 150 3291 Факс: (+998) 71 150 3292

Addresses Revised 11.03.2014

Grundfos companies

Page 64

98464187 0314

ECM: 1112473

www.grundfos.com

The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide. © Copyright Grundfos Holding A/S

Grundfos 72, 74, 78 Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. Symbols used in this document

3. Safety

4. Identification

4.1 Nameplate

4.2 Type key

5. Handling the pump

5.1 Lifting the pump

5.2 Lifting points

5.3 Raising pump to upright position

6. Torques, lubricants and special liquids

6.1 Common torques

6.2 Special torques and lubricants

6.3 Quantities of grease in bearings

6.4 Special liquids

7. Service tools

7.1 Standard tools

7.2 Special tools

7.3 Tightness test tools

7.4 Lifting tools

8. Service

8.1 General information

8.2 Pump cleaning and visual inspection

8.3 Annual maintenance

8.4 Oil check and oil change

8.5 Inspection and adjustment of impeller clearance

8.5.1 Submersible pumps, installation types S, C and ST

8.5.2 Dry-installed pumps, installation types D and H

9. Dismantling and assembly instructions

9.1 Checking and replacing the ca ble

9.1.1 Change of cable without adapter flange, method A

9.1.2 Change of cable with adapter flange, method B

9.2 Replacing the terminal board

9.2.1 Range 72

9.2.2 Range 74 and 78

9.3 Replacing the protection sensors

9.3.1 Moisture switch

9.3.2 Pt100 sensor in upper bearing bracket

9.3.3 Pt100 sensor on the stator

9.3.4 Pt100 sensor in lower bearing bracket

9.3.5 Water-In-Oil sensor (WIO)

9.4 Dismantling range 72

9.4.1 Removing the impeller and pump housing

9.4.2 Draining the oil

9.4.3 Removing the primary shaft seal

9.4.4 Removing the terminal box

9.4.5 Removing the cooling jacket

9.4.6 Removing the upper bearing bracket

9.4.7 Removing the upper bearing

9.4.8 Removing the shaft seal housing

9.4.11 Removing the lower bearings

9.4.9 Removing the secondary shaft seal

9.4.10 Removing the rotor

9.5 Assembling range 72

9.5.1 Fitting the lower bearings

9.5.2 Fitting the rotor

9.5.3 Fitting the secondary shaft seal

9.5.4 Fitting the shaft seal housing

9.5.5 Fitting the upper bearing

9.5.6 Fitting the upper bearing bracket

9.5.7 Fitting the cooling jacket

9.5.8 Fitting the terminal box

9.5.9 Fitting the primary shaft seal

9.5.10 Oil filling

9.5.11 Fitting the impeller and the pump housing

9.6 Dismantling range 74

9.6.1 Removing impeller and pump housing

9.6.3 Removing the primary seal

9.6.4 Removing the motor top cover

9.6.2 Draining the oil

9.6.5 Removing the cooling jacket

9.6.6 Removing the terminal box

9.6.7 Removing the upper bearing

9.6.8 Removing the shaft seal housing

9.6.9 Removing the secondary shaft seal

9.6.10 Removing the rotor

9.6.11 Removing the lower bearings