Viking KK825, K-825, KK823, K-827, KK827 User Manual

Electronic copies of the most current TSM issue can be found on the Viking Pump website at www.vikingpump.com

TECHNICAL SERVICE MANUAL

MAGNETIC DRIVE PUMPS

SERIES 823 – STEEL

825 – CAST IRON

827 – STAINLESS STEEL

SIZES K & KK

SECTION TSM 845

PAGE 1 Of 14

ISSUE f

CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Information. . . . . . . . . . . . . . . . . . . . 2

Special Information . . . . . . . . . . . . . . . . . . . 3

Maintenance . . . . . . . . . . . . . . . . . . . . . . 3

Disassembly: Pump. . . . . . . . . . . . . . . . . . . 4

Disassembly: Coupling . . . . . . . . . . . . . . . . . 6

Disassembly & Assembly

of MD-C Series Bearing Housing . . . . . . . . . . 8

Installation of Bushings . . . . . . . . . . . . . . . . .10

Assembly: Coupling. . . . . . . . . . . . . . . . . . .10

Adjusting Head Gasket End Clearance . . . . . . . . .11

Pump Rotation . . . . . . . . . . . . . . . . . . . . 11

Pressure Relief Valve . . . . . . . . . . . . . . . . . .11

Troubleshooting. . . . . . . . . . . . . . . . . . . . .13

Warranty . . . . . . . . . . . . . . . . . . . . . . . .14

WARNING !

Persons with surgical implants of a
metallic or electronic nature should
avoid working on pump – especially the
inner magnet assembly.

Model Number Chart

UNMOUNTED UNITS

Units are designated by the

K-823 , 825 , 827

KK823 , 825 , 827

This manual deals only with Series 823, 825 and 827 magnetic
drive pumps and couplings. Refer to Figures 1 thru 23
for general configuration and nomenclature used in this
manual. Pump specifications and recommendations are
listed in Catalog Section 845.

unmounted pump model numbers
followed by a letter(s) indicating
drive style.

B = Bracket Mount
R = Viking Reducer Drive
P = Commercial Speed Reducer
(Example: KK-827-MD-C80R)

TABLE 1

INTRODUCTION

The illustrations used in this manual are for identification
purposes only and should not be used for ordering parts.
Secure a parts list from the factory or a Viking® representative.
Always give complete name of part, part number or material
with model number and serial number of pump when ordering
repair parts. The unmounted pump or pump unit model
number and serial number can be found on the nameplate.

In the Viking® model number system, the basic size letters
are combined with the series (823, 825, 827), indicating basic
pump construction material (steel, cast iron, or stainless steel
respectively). See Model Number Chart.

FIGURE 1
K & KK-827 (stainless steel) MD-C80 B
Bearing Carrier, Footed Bracket and
Mounted Pump with Flanged Ports.

FIGURE 2
K & KK-825 (cast iron) MD-C80 R
Unit complete with Motor, “B”
Gear Reducer, Bearing Carrier
mounted to base with Mounted
Pump featuring Tapped Ports.

VIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USAVIKING PUMP, INC. • A Unit of IDEX Corporation • Cedar Falls, IA 50613 USA

SAFETY INFORMATION

INCORRECT INSTALLATION, OPERATION OR MAINTENANCE OF EQUIPMENT MAY CAUSE SEVERE

PERSONAL INJURY OR DEATH AND/OR EQUIPMENT DAMAGE AND MAY INVALIDATE THE WARRANTY.

This information must be read fully before beginning installation, operation or maintenance and must be
kept with the pump. All installation and maintenance must be undertaken by suitably trained or qualified
persons only.

Warning - Safety instructions which

shall be considered for reasons of safe
operation of the pump or pump unit and/
or protection of the pump or pump unit
itself are marked by this symbol.

Symbol

Legend :

Danger - Failure to follow the listed

precautionary measures identified by
this symbol may result in serious injury

!

or death.

WARNING

!

!

!

!

!

WARNING

!

!

DO NOT OPERATE PUMP IF:

– The front cover is not installed correctly.

– Any guards are missing or incorrectly installed.

– The suction or discharge piping is not connected.

DO NOT place fingers, etc. into the pumping chamber
or its connection ports or into any part of the drive train
if there is ANY possibility of the pump shafts being
rotated. Severe injury will occur.

DO NOT exceed the pumps rated pressure, speed, and
temperature, or change the system/duty parameters
from those for which the pump was originally supplied,
without confirming its suitability for the new duty.

INSTALLATION AND OPERATION OF THE PUMP
MUST ALWAYS COMPLY WITH HEALTH AND
SAFETY REGULATIONS.

Rare earth magnets used in couplings have
extremely strong magnetic fields capable of
changing performance or damaging items such as:
Pacemakers, Metal Implants, Watches, Computers
& Disks, and Credit Cards

Completely assembled magnetic couplings will
not affect items listed above - only disassembled
components.

There are no known harmful effects of these
magnetic fields on the human body.

A device must be incorporated into the pump, system,
or drive to prevent the pump exceeding its stated duty
pressure. It must be suitable for both directions of
pump rotation where applicable. Do not allow pump
to operate with a closed/blocked discharge unless a
pressure relief device is incorporated. If an integral
relief valve is incorporated into the pump, do not allow
re-circulation through the relief valve for extended
periods.

The mounting of the pump or pump unit should be
solid and stable. Pump orientation must be considered
in relation to drainage requirements. Once mounted,
shaft drive elements must be checked for correct
alignment. Rotate pump shaft by at least one full
revolution to ensure smoothness of operation.
Incorrect alignment will produce excessive loadings
and will create high temperatures and increased noise
emissions. Do not use any drive arrangements which
cause sideloading of the drive shaft.

The installation must allow safe routine maintenance
and inspection (to check for leakage, monitor
pressures, etc) and provide adequate ventilation
necessary to prevent overheating.

WARNING

WARNING

WARNING

!

!

!

!

!

!

Before operating the pump, be sure that it and all
parts of the system to which it is connected are clean
and free from debris and that all valves in the suction
and discharge pipelines are fully opened. Ensure that
all piping connecting to the pump is fully supported
and correctly aligned with its relevant connections.
Misalignment and/or excess loads will cause severe
pump damage.

Be sure that pump rotation is correct for the desired
direction of flow.

DO NOT INSTALL THE PUMP INTO A SYSTEM
WHERE IT WILL RUN DRY (I.E. WITHOUT A
SUPPLY OF PUMPED MEDIA).

Pressure gauges/sensors are recommended, next
to the pump suction and discharge connections to
monitor pressures.

Caution must be taken when lifting the pump. Suitable
lifting devices should be used as appropriate. Lifting
eyes installed on the pump must only be used to lift
the pump, not pump with drive and/or baseplate. If
pump is baseplate mounted, the base plate must be
used for all lifting purposes. If slings are used for lifting,
they must be safely and securely attached. For weights
of bare shaft pumps refer to catalog.

DO NOT attempt any maintenance or disassembly of
the pump or pump unit without first ensuring that :

– The pump is fully isolated from the power source

(electric, hydraulic, pneumatic).

– The pumping chamber, relief valve and any

shaft seal support system are depressurized and
purged.

– Any temperature control devices (jackets, heat-

tracing, etc) are fully isolated, that they are
depressurized and purged, and components are
allowed to reach a safe handling temperature.

DO NOT attempt to dismantle a pressure relief valve
which has not had the spring pressure relieved or is
mounted on a pump that is operating. Serious personal
injury or death and/or pump damage may occur.

DO NOT loosen or undo the front cover, any
connections to the pump, shaft seal housings,
temperature control devices, or other components,
until sure that such action will not allow the unsafe
escape of any pressurized media.

Pumps and/or drives can produce sound power levels
exceeding 85 dB(A) under certain operating conditions.
When necessary, personal protection against noise
must be taken.

Avoid any contact with hot parts of pumps and/or
drives which may cause injury. Certain operating
conditions, temperature control devices (jackets, heat­tracing, etc.), bad installation, or poor maintenance
can all promote high temperatures on pumps and/or
drives.

SECTION TSM 845 ISSUE F PAGE 2 OF 14

SPECIAL INFORMATION

DANGER !

Before opening any Viking pump liquid
chamber (pumping chamber, reservoir,
etc.) Be sure:

1. That any pressure in the chamber has
been completely vented through the
suction or discharge lines or other
appropriate openings or connections.
(See detailed procedure for venting
the pumps, pages 4, 5 and 6).

2. That the driving means (motor,
turbine, engine, etc.) has been
“locked out” or made otherwise non­operational so that it cannot be
inadvertently started while work is
being done on the pump.

DISCHARGE

SUCTION

RELIEF VALVE ADJUSTING SCREW CAP

FIGURE 3

3. That you know what liquid the
pump has been handling and the
precautions necessary to safely
handle the liquid. Obtain a material
safety data sheet (MSDS) for the
liquid to be sure these precautions
are understood.

Failure to follow above listed
precautionary measures may result in
serious injury or death.

ROTATION: Viking Mag-Drive® pumps are designed to run
in the direction indicated on the nameplate only. If rotation
must be reversed, see “Pump Rotation” on page 10.

PRESSURE RELIEF VALVES:

1. Relief valves are mounted on the head of K and KK
size pumps. Relief Valves are not available on jacketed
heads.

2. If a Relief Valve is not furnished on the pump, some
means of over protection such as an in-line relief valve
should be provided. Do not rely on magnets decoupling
for protection from over pressure. This may result in
damage to magnets, pump or other equipment.

3. Relief valve adjusting screw cap must always point
towards suction side of pump. If pump rotation is
reversed, remove pressure relief valve and turn end for
end (See “Pump Rotation” on page 10 for additional
steps required for proper operation). See Figure 3.

4. Pressure relief valves cannot be used to control pump
flow or regulate discharge pressure.

For additional information on pressure relief valves, refer

to Technical Service Manual TSM000 and Engineering
Service Bulletin ESB-31.

MAINTENANCE

CAUTION !

Rare earth magnets used in these
couplings have extremely strong
magnetic fields capable of changing the
performance or damaging items such as
the following:

Pacemakers
Metal Implants
Watches
Computers & discs
Credit Cards

Completely assembled magnetic
couplings will not affect items listed
above.

Altered performance or damage can
occur only when the coupling halves are
separated.

There are no known harmful effects of
these magnetic fields on the human
body.

Series 823, 825 and 827 pumps are designed for long,
trouble-free service life under a wide variety of application
conditions with a minimum of maintenance. The points listed
below will help provide long service life.

SECTION TSM 845 ISSUE F PAGE 3 OF 14

CLEANING PUMP: Keep pump as clean as possible. This
will facilitate inspection, adjustment and repair work.

STORAGE: If pump and coupling are to be stored, drain pump
and pour non-detergent SAE 30 weight oil into the pump port.
Apply grease to the pump or the coupling shaft extension, if
present or accessible. Viking suggests rotating pump shaft by
hand one complete revolution every 30 days to circulate the
oil. The coupling should be stored in a dry area.

Note: if the liquid to be pumped reacts with oil, use an
acceptable alternate.

SUGGESTED REPAIR TOOLS: The following tools are
required to properly repair Series 823, 825, and 827 pumps.
These tools are in addition to standard mechanics’ tools such
as open-end wrenches, pliers, screwdrivers, etc. Most of the
items can be obtained from an industrial supply house.

1. Soft face hammer

2. Allen wrenches

3. External Snap ring pliers - 2-810-029-375

4. Internal Snap ring pliers - 2-810-047-999

5. Feeler gauge set

6. Arbor Press

7. Brass Bar

8. Hand Knobs - 2-790-046-999 (2 Required)

9. Standard 5/16” 12 point socket

DANGER !

Before opening any Viking pump liquid
chamber (pumping chamber, reservoir,
etc.) Be sure:

1. That any pressure in the chamber has
been completely vented through the
suction or discharge lines or other
appropriate openings or connections.

(See detailed procedure for venting

the pumps, pages 4, 5 and 6).

2. That the driving means (motor,
turbine, engine, etc.) has been
“locked out” or otherwise made non­operational so that it cannot be
inadvertently started while work is
being done on the pump.

3. That you know what liquid the
pump has been handling and the
precautions necessary to safely
handle the liquid. Obtain a material
safety data sheet (MSDS) for the
liquid to be sure these precautions
are understood.

DISASSEMBLY: PUMP

1. Refer to Figures 4, 5 & 6 for names of parts.

2. Mark head, casing, and bracket before disassembly to

insure proper reassembly. The idler pin, which is offset in
the pump head, must be positioned toward and an equal
distance from port connections to allow for proper flow of
liquid through the pump.

3. Remove the head capscrews.

CANISTER

O-RINGS

OUTER MAGNET

ASSEMBLY

BEARING
CARRIER

ASSEMBLY

CANISTER

Failure to follow above listed
precautionary measures may result in
serious injury or death.

BALANCE

PLATE

BRACKET

BUSHINGS

ROTOR

CASING

IDLER PIN

PRESSURE
RELIEF
VALV E

BRACKET

INNER MAGNET

ASSEMBLY

CUTAWAY VIEW MAG-DRIVE PUMP, MODEL KK-825 MD-80 B ILLUSTRATED

SECTION TSM 845 ISSUE F PAGE 4 OF 14

BRACKET

FIGURE 4

IDLER

HEAD

HEAD

GASKET

4. Remove head from pump. Do not allow idler to fall from

idler pin. Tilt top of head back when removing to prevent
this. Avoid damaging head gasket set, all gaskets are
required to maintain end clearance.

5. Remove idler and bushing assembly. If idler bushing
needs replacing, see “Installation of Bushings”
page 9. If further disassembly is required pump must
be separated from coupling. Refer to “Disassembly:

Coupling,” on page 6, before proceeding with Step 6.

6. After inner magnet is removed then remove key and

external retaining ring from the shaft. Rotor and shaft
may now be extracted by tapping on end of the shaft
with a soft face hammer (if a soft faced hammer is
unavailable a regular hammer may be used with a piece
of hardwood).

7. Mark the location and orientation of the Balance plate
before removing by pulling out. (The balance plate may
not be removable in the 825 series).

The casing should be examined for wear, particularly in the
area between ports. All parts should be checked for wear
before pump is assembled.

When making major repairs, such as replacing a rotor and
shaft, it is advisable to also install a new head and idler pin,
idler and bushing, and casing bushings. See “Installation of

Bushings” on page 9.

Clean all parts thoroughly and examine for wear or damage.
Check bushings, idler pin and balance plate; replace if
necessary.

ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART

1 Bracket Gasket - Primary 10 Casing 19 Head Gasket

2 Bracket Gasket 11 Capscrew for Inner Magnet 20 Idler Pin

3 Orifice 12 Lockwasher 21 Head & Pin

4 Bracket 13 Washer 22 Pipe Plug

5 Capscrews for Casing 14 External Retaining Ring 23 Capscrews for Head

6 Casing Gasket 15 Key 24 Gaskets for Relief Valve

7 Bracket Bushings 16 Rotor & Shaft 25 Relief Valve

8 Balance Plate (Maybe Not in 825) 17 Idler Bushing 26 Capscrews for Relief Valve

9 Pipe Plugs 18 Idler & Bushing

FIGURE 5

K & KK MAG DRIVE PUMP

SECTION TSM 845 ISSUE F PAGE 5 OF 14