Viking MAG DRIVE 855 User Manual

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TECHNICAL SERVICE MANUAL

SERIES 855

Sizes AS, AK, AL, KE, KKE

SECTION TSM

PAGE

ISSUE

1 OF 16

685.2

CONTENTS

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

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

Maintenance ................................................................. 4

Parts Identification Drawings ........................................ 5-7

Disassembly of Pump ................................................... 7

Disassembly of Coupling .............................................. 8

Disassembly / Assembly Bearing Carrier ..................... 9-10

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

Assembly of Pump........................................................ 10-11

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

Assembly of Couplings ................................................. 12

Adjusting End Clearance .............................................. 13

Pressure Relief Valve Instructions ................................ 13-14

Troubleshooting ............................................................ 15

Warranty ....................................................................... 16

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 PUMPS UNITS

AS-855U, AS-855M,

AK-855U, AK-855M

AL-855U, AL-855M

KE-855U, KE-855M

KKE-855U, KKE855M

Units are designated by the unmounted pump model numbers followed by the magnetic coupling size and a letter indicating drive style.

(Example: AK-855MA MD2 B50 M )

D = Direct Drive, Base Mounted M = Motor, Face Mounted B = Bearing Carrier R = Viking Reducer Drive P = Commercial Reducer Drive

See Page 4 for complete description of the model number

TABLE 1

This information must be read fully before beginning any maintenance or repair of the pump. All maintenance or repair must be done by SUITABLY TRAINED or qualified persons only.

INTRODUCTION

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

This manual deals only with Series 855 magnetic drive pumps. Refer to Figures 1 through 22 for general configuration and nomenclature used in this manual. Pump specifications and recommendations are listed in Catalog Section 685.

In the Viking model number system, the basic size letters (AS, AK, AE etc.) are combined with the series number (855) indicating basic pump construction material.

FIGURE 1

SERIES AK855UB MD2-32 B

Pump with Bearing Carrier

FIGURE 2

AK SERIES 855UB MD2-14 M

Pump with Motor Directly Mounted to the Bracket

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

SAFETY INFORMATION AND INSTRUCTIONS

IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY OR DEATH AND/OR RESULT IN DAMAGE TO PUMP AND/OR OTHER EQUIPMENT. VIKING’S WARRANTY DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION, OPERATION OR MAINTENANCE.

THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION, OPERATION OR MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP. PUMP MUST BE INSTALLED, OPERATED AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS.

THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES.

Symbol Legend :

WARNING

Danger - Failure to follow the indicated

instruction may result in serious injury

or death.

BEFORE opening any liquid chamber (pumping chamber, reservoir, relief valve adjusting cap fitting, etc.) be sure that :

● Any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections.

● The pump drive system means (motor, turbine, engine, etc.) has been “locked out” or otherwise been made non-operational so that it cannot be started while work is being done on the pump.

● You know what material the pump has been handling, have obtained a material safety data sheet (MSDS) for the material, and understand and follow all precautions appropriate for the safe handling of the material.

BEFORE

are in place.

DO NOT operate pump if the suction or discharge piping is not connected.

DO NOT place fingers 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.

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

BEFORE

● It is clean and free from debris

● all valves in the suction and discharge pipelines

are fully opened.

● All piping connected to the pump is fully supported

and correctly aligned with the pump.

● Pump rotation is correct for the desired direction

of flow.

operating the pump, be sure all drive guards

operating the pump, be sure that:

WARNING

Warning - In addition to possible serious

injury or death, failure to follow the indicated instruction may cause damage to pump and/or other equipment.

INSTALL pressure gauges/sensors next to the pump suction and discharge connections to monitor pressures.

USE extreme caution when lifting the pump. Suitable lifting devices should be used when appropriate. Lifting eyes installed on the pump must be used only to lift the pump, not the pump with drive and/or base plate. If the pump is mounted on a base plate, the base plate must be used for all lifting purposes. If slings are used for lifting, they must be safely and securely attached. For weight of the pump alone (which does not include the drive and/or base plate) refer to the Viking Pump product catalog.

DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is mounted on a pump that is operating.

AVOID contact with hot areas of the pump and/or drive. Certain operating conditions, temperature control devices (jackets, heat-tracing, etc.), improper installation, improper operation, and improper maintenance can all cause high temperatures on the pump and/or drive.

THE PUMP must be provided with pressure protection. This may be provided through a relief valve mounted directly on the pump, an in-line pressure relief valve, a torque limiting device, or a rupture disk. If pump rotation may be reversed during operation, pressure protection must be provided on both sides of pump. Relief valve adjusting screw caps must always point towards suction side of the pump. If pump rotation is reversed, position of the relief valve must be changed. Pressure relief valves cannot be used to control pump flow or regulate discharge pressure. For additional information, refer to Viking Pump’s Technical Service Manual TSM 000 and Engineering Service Bulletin ESB-31.

THE PUMP must be installed in a matter that allows safe access for routine maintenance and for inspection during operation to check for leakage and monitor pump operation.

SECTION TSM 685.2 ISSUE C PAGE 2 OF 16

SPECIAL INFORMATION

DANGER !

For additional information on pressure relief valves, refer to Technical Service Manual TSM000 and Engineering Service Bulletin ESB-31.

Before opening any Viking pump liquid chamber (pumping chamber, reservoir, relief valve adjusting cap fitting 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.

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

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

RELIEF VALVE ADJUSTING SCREW CAP

SUCTION

FIGURE 3

RELIEF VALVE POSITION

DISCHARGE

CAUTION !

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

ROTATION: Viking Mag Drive® pumps are designed to run in either direction. See PUMP ROTATION, page 11.

PRESSURE RELIEF VALVES:

1. Viking pumps are positive displacement pumps and must be provided with some sort of pressure protection. This may be a relief valve mounted directly on the pump, an inline pressure relief valve, a torque limiting device or a rupture disk. Do not rely on decoupling of magnets for protection from over pressure; this may result in damage to the magnets, pump, or other equipment.

2. Relief valves are mounted as standard on the casing of AS, AK,AL,KE and KKE size pumps.

3. If the pump rotation is to be reversed during operation, pressure protection must be provided on both sides of the pump.

4. The relief valve adjusting screw cap must always point towards the suction side of the pump. See

Figure 3. the pressure relief valve and turn end for end (see PUMP ROTATION, page 11 for additional information.

5. Pressure relief valves cannot be used to control pump

flow or regulate discharge pressure.

If the pump rotation is reversed, remove

Pacemakers Metal Implants Watches Computers & disks 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.

SECTION TSM 685.2 ISSUE C PAGE 3 OF 16

BEARING CARRIER ASSEMBLY (Optional)

SHAFT

CANISTER

CANISTER O-RING

TEMPERATURE

PROBE HOLE

CASING BUSHING

RELIEF VALVE

(shown with optional RV coverplate)

ROTOR

HEAD GASKET SEAL

HEAD

OUTER MAGNET ASSEMBLY

BRACKET

INNER MAGNET ASSEMBLY

FIGURE 4

CUTAWAY VIEW MAG DRIVE PUMP, MD2-B

WITH BEARING CARRIER ILLUSTRATED

MAINTENANCE

Series 855 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.

CLEANING PUMP:

Keep the pump as clean as possible. This will facilitate inspection, adjustment and repair work.

LUBRICATION:

Some bearing carriers require external lubrication. This must be applied slowly with a handgun to lubrication fittings every 500 hours of operation with multi-purpose grease, NLGI # 2. Do not over-grease. Applications involving very high or low temperatures will require other types of lubrication. Refer to ESB-515. Consult factory with specific lubrication questions.

STORAGE:

If the pump and coupling are to be stored, drain the 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.

GAUGE PORT BOSS

IDLER PIN

IDLER

CASING

Viking suggests rotating the pump shaft every 30 days to circulate the oil in the pump. 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 855 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. Metric Allen wrenches (for set screws)

3. Torque Wrench with a locknut socket

4. External snap ring pliers - (Viking Part # 2-810-029-375)

5. Internal snap ring pliers - (Viking Part # 2- 810-047-999)

6. Arbor press

7. Brass bar

8. Hook style spanner wrench

SECTION TSM 685.2 ISSUE C PAGE 4 OF 16

Series

AS 8 5 5 M B-MD2 B14 B

Size

(Nominal displacement)

Material

5 = Cast Iron

Port Design M= DIN

U= ANSI

Coupling Size - Pump Related

A size = Used on GS, GG, HJ or HL B size = Used on HJ, HL, AS, AK or AL C Size = Used on AS, AK, AL, KE, or KKE

AS AK AL

KE KKE

FIGURE 5

MODEL NUMBER SYSTEM

Drive Congurations

M = Motor, Face Mount D = Direct Drive, Base Mounted B = Bearing Carrier R = Viking Reducer Drive P = Commercial Reducer Drive

Magnetic Coupling Size and

Torque Specication - Drive

A 4 and 9 Ft-Lbs B 14,32 and 50 Ft-Lbs C 40,90, 135 and 180 Ft-Lbs

Magnetic Coupling Design

Second generation and not interchangable with previous design.

FIGURE 6

EXPLODED VIEW – SIZES AS, AK, AL, KE & KKE MAG-DRIVE PUMPS

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

1 Locknut 37 Idler 53 Locating Pin

21 Set Collar 38 Idler Bushing 60 Thrust Washer - 2 Req’d

25 Casing Bushing 39 Idler Pin 61 Machine Screws (metric) - 2 Req’d

30 Pipe Plug - 2 Req’d 40 Head and Idler Pin Assembly 62 Drive Key

32 Casing and Bushing Assembly 43

33 Casing Stem O-ring 45 Relief Valve Gaskets - 2 Req’d

35 Head O-ring 46

36 Rotor and Shaft Assembly 47 Relief Valve

Capscrews (metric) for Head 6 Req’d

Capscrews (metric) for Relief Valve

- 6 Req’d

63 Shims for Head (metal)

TABLE 2

SECTION TSM 685.2 ISSUE C PAGE 5 OF 16

MAGNETIC COUPLING OPTIONS

Pump Size Magnetic Coupling

Sizes

AS B, C

AK B, C

AL B, C

KE C

KKE C

TORQUE RATINGS AND DRIVER CONNECTION OPTIONS

Magnetic Coupling Sizes

Torque Ratings (Ft-Lbs)

• 14

• 32

• 50

• 40

• 90

• 135

• 180

IEC B-5 Flange

Motor Mounts

Close-Coupled Long-Coupled

• 100/112

• 132

•132

•160/180

TABLE 3

COUPLING TORQUE AND SIZE OPTIONS

NEMA Motor

Mounts

• 182 / 184TC

• 213 / 215TC

• 254 / 256TC

• 213 / 215TC

• 254 / 256TC

• 284 / 286TC

Bearing

Carrier

Yes

FIGURE 7

M DRIVE CONFIGURATION

MD2- B SERIES COUPLING AND BEARING CARRIER COMPONENTS

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION

601 Bolt-on Hub with Hardware 607 Capscrews (metric) for Pump - 4 Req’d 613 Drive Key - Outboard Side

602 Outer Magnet Assembly 608 Canister and Bushing Assembly 614 Shaft

603 Bracket 609 Inner Magnet Assembly 615 Drive Key - Inboard Side

Capscrew (jackscrew) for Disassembly

604

(metric)

605 Lifting Eye 611 Bearing Carrier Housing 617 Spacer

606 Pipe Plug for Sensor Hole 612 External Retaining Ring - 2 Req’d 618 Internal Retaining Ring

Capscrews (metric) for Motor or Bearing

610

Carrier - (4) Req’d

616 Ball Bearing - 2 Req’d

TABLE 4

SECTION TSM 685.2 ISSUE C PAGE 6 OF 16

FIGURE 8

M DRIVE CONFIGURATION

MD2- C SERIES COUPLING AND BEARING CARRIER COMPONENTS

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION

601 Bolt-on Hub with Hardware 611 Bearing Carrier Housing 623 Outer Bearing Spacer

602 Outer Magnet Assembly 613 Drive Key - Outboard Side 624 Tapered Roller Bearing - 2 Req’d

603 Bracket 614 Shaft 625 Lip Seal (Inner)

Capscrew (jackscrew) for Disassembly

604

(metric)

605 Lifting Eye 617 Inner Bearing Spacer 627 Insert - 2 Req’d

606 Pipe Plug for Sensor Hole 619 Locknut 628 Grease Fitting

607 Capscrews (metric) for Pump - 4 Req’d 620 Lockwasher 629 Adapter (NEMA motor only)

608 Canister and Bushing Assembly 621 End Cap 630

609 Inner Magnet Assembly 622 Lip Seal (Outer)

Capscrews (metric) for Motor or

610

Bearing Carrier - 4 Req’d (284 Motor Frame, - 5 req’d)

615 Drive Key - Inboard Side 626 Setscrew - 2 Req’d

Capscrews (metric) for Adaptor - 4 Required

TABLE 5

PUMP DISASSEMBLY

6. Remove the idler and bushing assembly. If the idler

WARNING!

Refer to DANGER & CAUTION listed on page 2 before proceeding.

bushing needs to be replaced, see “INSTALLATION OF BUSHINGS” on page 10.

If further disassembly is required, the pump must be separated from coupling. Refer to “DISASSEMBLY OF COUPLING” on page 8 before proceeding with Step 7.

1. To drain the liquid being pumped, remove the two (2) drain plugs located in the bottom of the casing. Once the liquid has drained replace the plugs.

2. Refer to Figures 4, 6, 7 & 8 for names of parts.

3. Mark the head and casing before disassembly to insure

proper reassembly.

4. To inspect the head and pin assembly and idler and bushing assembly, remove the head capscrews.

5. Remove the head from the pump. Do not allow the idler to fall from the idler pin. Tilt the top of the pump head back when removing to prevent this. Avoid damaging the head shim set since all shims are required to maintain end clearance.

7. With the inner magnet removed, now remove the pump shaft key. Remove the outer thrust washer. The rotor and shaft may now be removed by tapping on the end of the shaft with a soft face hammer (If a soft face hammer is not available a regular hammer may be used with a piece of hardwood).

8. Remove the inner thrust washer from behind the rotor.

The casing should be examined for wear, particularly in the area between the ports. Clean all other parts thoroughly and examine for wear or damage. Check the bushings, idler pin and thrust washers; replace if necessary.

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 10.

SECTION TSM 685.2 ISSUE C PAGE 7 OF 16

DISASSEMBLY OF COUPLING

Series MD2-B and MD2-C, All Sizes

(4) 12mm Screw

DO NOT PLACE FINGERS HER

Canister Bushing

Button Head Screws

Canister

O-ring

Canister and Casing Drain Holes

FIGURE 9

PUMP, INNER MAGNET AND CANISTER ASSEMBLY

1. Remove the piping to the ports and remove the

capscrews securing the pump to the bracket. Support the pump with an overhead hoist if possible. Use the M10 x 120 capscrew (jackscrew) in the bracket to separate the inner magnet from the outer. (See Figure

Sequence 10).

CAUTION !

Use extreme caution, when pulling the inner magnet away from the outer magnet (see Figure 10). Do not place your fingers between the pump mounting flange and the face of the bracket. If you do not completely pull the pump out it will snap back and could pinch a finger or hand. Once the inner magnet is removed from the bracket be careful setting it down as it will

attract any iron or steel object.

M10X120 CAPSCREW

DO NOT PLACE FINGERS HERE

M10x120 CAPSCREW

Locknut

FIGURE 10

Inner Magnet

PUMP AND BRACKET SEPARATION SEQUENCE

Buttonhead Screws

2. The canister will contain some liquid, therefore use care while removing from the pump and pull it straight off.

3. Remove the two 6mm buttonhead machine screws and the set collar. Insert a brass bar through a port between two rotor teeth and remove the locknut (See Figure 11). Slide the inner magnet off the shaft. Do not forget this is a very strong magnet. If further pump disassembly is required, refer to Step 7 of PUMP DISASSEMBLY.

4. Do not remove the O-ring unless it is bad, especially if PTFE (derivative) encapsulated. If a new O-ring is required, follow instructions in the ASSEMBLY section on page 10.

5. You should be able to visually inspect the outer magnets from the end of the bracket. If removal is necessary, start by removing the (4) capscrews (See Figure 12) and separate the bracket from the motor or bearing carrier. Loosen the 2 setscrews on the outer shell hub and slide the outer magnet assembly off the shaft. If the unit features a bearing carrier, refer to Page 9 for disassembly of the bearing carrier housing.

SECTION TSM 685.2 ISSUE C PAGE 8 OF 16

Set Collar

FIGURE 11

INNER MAGNET AND LOCKNUT ASSEMBLY

Capscrews

Bracket

Motor or Bearing Carrier

FIGURE 12

MOTOR (OR BEARING CARRIER) AND BRACKET

DISASSEMBLY / ASSEMBLY OF BEARING CARRIER

Bearing Carrier for MD2-B Couplings

Bearing Carrier Housing

Spacer

Ball Bearings

External Retaining Rings

MD2-B OUTER MAGNET, BOLT ON HUB

AND BEARING CARRIER

Internal Retaining Ring

Set Screw

Outer Magnet

Bolt-on Hub

“A”

FIGURE 13

Bearing Carrier for MD2-C Couplings

Bearing Carrier

Lipseal

Housing

Set Screw

Bolt-on Hub

FIGURE 14

Inner Key

“A”

Outer Magnet

Retaining End Cap and

Lockwasher and Locknut

Tapered Roller Bearing, (Outer)

Tapered Roller

Bearing, (Inner)

Setscrew

Spacer

MD2-C OUTER MAGNET, BOLT ON HUB

AND BEARING CARRIER

DISASSEMBLY

The bearing carrier for an MD2 B coupling features two sealed ball bearings along with the outer magnet assembly. If further disassembly of this unit is required, reference Figure

7 on page 6 and Figure 13

then proceed as follows:

1. Remove the internal retaining ring. Using a press, press the shaft out of the housing.

2. Remove the external retaining rings from shaft. Place the unit into the press and push out shaft out of the bearings.

ASSEMBLY

1. Place some Loctite® on the O.D. of the first bearing and

press into the housing bore. Position the bearing spacer in the bore and insert the second bearing. Center the bearing spacer then press in the shaft with one external retaining ring on shaft. Press down until the ring contacts the bearing race, then install the second ring. Install the internal retaining ring into the bearing housing.

2. Slide the outer magnet assembly onto the pump shaft. Locate the outer magnet per dimension “A” listed below then tighten the two setscrews.

“B” Coupling Outer Magnet

Location Dimension*

Pump Design “A” Dim.

U.S. Inch Design 8.49 inches

Metric Design 196.4 mm

DISASSEMBLY

The bearing carrier for the MD2 C coupling features two tapered roller bearings secured by a threaded end cap. The unit is greased externally using the grease fitting. If further disassembly is required, reference Figure 8 on page 7 and

Figure 14

1. Remove the two setscrews from the bolt-on hub and slide

2. Place the inboard side of the shaft in a vise with padded

3. Loosen the two setscrews retaining the end cap. Back

4. One lip seal is pressed into the end cap and the other is

*Dimensions are not the same between designs

Loctite® is a trademark of

, then proceed as follows:

the outer magnet off of the shaft. Remove the outboard drive key in shaft.

jaws. Bend the lockwasher tab up and gently tap the locknut in a counterclockwise direction. Remove the locknut and lockwasher.

out the end cap completely. Pull or gently tap the shaft out the back of the bearing housing. Be sure to keep the cup and cone of the outer bearing together. If either the cup or cone requires replacing, it is recommended to replace as a set. The inner cone will probably stay in the housing unless it is to be replaced.

pressed into the bearing housing. Do not remove the lipseals unless they require replacement. If removed, pay close attention to the orientation as shown in

Figure 14

when installing the new lip seals.

Henkel Consumer Adhesives, Inc.

SECTION TSM 685.2 ISSUE C PAGE 9 OF 16

Bearing Carrier for MD2-C Couplings (Cont.)

INSTALLATION OF BUSHINGS

ASSEMBLY

Depending on the condition of the bearings, either replace or repack existing bearings by cleaning and packing with multipurpose NLGI # 2 grease. Replace the lip seals if necessary.

See Figure 14, page 9

1. Place the bearing housing milled-face down with cast

surface up. If the inner lip seal was removed, install with the cup up. Install the cup of inner bearing into housing (cup up).

2. Slide the inner tapered roller bearing cone onto the shaft (cone down) and then the inner spacer followed by the outer cone (cone up).

3. Guide shaft into the housing and into the inner lip seal. Slide the tapered roller bearing outer cup into the housing (cup down) and the bearing spacer collar onto shaft.

4. Thread in the end cap until it meets the outer cup. Install the lockwasher and locknut. Secure the end of the shaft in a vice with padded jaws then tighten the locknut. Tighten the end cap until there is considerable drag on the bearings, then back off the end cap approximately 10°. Secure the end cap into position by tightening the two set screws.

5. Tighten the locknut again, then bend over the appropriate lockwasher tab.

6. Install the inboard drive key, then slide the magnet onto the shaft. Locate the outer magnet per dimension “A” listed below. Tighten the two setscrews to lock into proper position.

for lipseal orientation.

CARBON GRAPHITE

The canister bushing (see Figure 9 on page 8) requires a special fixture for proper assembly so the bushing is only sold as part of the canister assembly.

If attempting to install the carbon graphite idler or casing bushing, extreme care must be taken to prevent breaking. Carbon graphite is a brittle material and easily cracked. If cracked, the bushing will quickly disintegrate. Using a lubricant on the bushing and mating part will help facilitate installation.

Figure 15

after installation. This will require a special fixture for proper position. Improper location may result in a pump with excessive slip or requiring a large number of shims. The additional precautions listed below must be followed for installation:

1. An arbor press must be used for installation.

2. Be certain the bushing is started straight.

3. Do not stop the pressing operation until the bushing is in

4. After installation, check the bushing for cracks.

shows the proper position of the casing bushing

the proper position; starting and stopping will result in a cracked bushing.

Inch

.245

6.223

.242

6.147

“C” Coupling Outer Magnet

Location Dimension

Pump Design “A” Dim.

U.S. Inch Design 10.43 inches

Metric Design 265 mm

SECTION TSM 685.2 ISSUE C PAGE 10 OF 16

Casing

FIGURE 15

CASING BUSHING POSITIONING

ASSEMBLY OF PUMP

Use a suitable lubricant compatible with the fluid being handled when reassembling the pump.

Inspect all parts, especially drilled holes in the casing (for draining) to make sure they are not plugged. Replace any worn parts, remove any burrs, and clean all parts before assembling the pump.

1. If the canister O-ring needs to be replaced, apply a lubricant to the O-ring and place it into the O-ring groove. If the O-ring is PTFE (derivative) encapsulated, follow these special instructions.

Do not attempt to reuse a PTFE (derivative) encapsulated O-ring if it has been removed. Immerse a new O-ring in boiling water for a few minutes. Remove it from the water and stretch out the O-ring so it will fit onto the casing hub without forcing it over a sharp edge. Run hot water* over the O-ring until it shrinks down tight onto the pilot of the pump. Dry with compressed air.

2. Clean the rotor and shaft so it is free of dirt, grit and other debris and apply lubricant. Place one thrust washer onto shaft so that the blind hole in thrust washer will line up with the drive pin on the back of the rotor. Push the rotor and shaft it into the casing as far as it will go.

3. Slide the second thrust washer onto the shaft, drive hole facing out and then install the key into the shaft.

4. Slide the inner magnet onto the shaft and engage the pin of the magnet into the hole of the thrust washer. Install the locknut, beveled edge out. Tighten the locknut to the torque value given in Table 6. Place a mark on the trailing edge of the locknut slot. Refer to Figure 16. Back off the locknut until the leading edge of that same slot lines up with the mark. This will establish the proper clearance for the thrust washers.

5. Place the set collar on the locknut and install the two machine screws.

END

(inch)

0.005

SET OF HEAD

SHIMS INCLUDES

(1) .007 (1) .005 (2) .002 (2) .001

NORMAL

CLEARANCE

AS, AK, AL 855

KE, KKE 855

End Clearances are adequate for viscosities up to 2500 SSU / 540 cSt (SAE 40 lube oil at room temperature). Higher viscosities require additional clearances. As a general rule the end clearance is doubled for higher viscosities. For specific recommendations for end clearance for viscosity or for operating temperatures above 225 °F (107 °C), check with your Viking representative or consult the factory.

TABLE 7

7. Coat the idler pin with a suitable lubricant and place

the idler on the idler pin in head. Make sure the O-ring for the head is installed (In the O-ring is PTFE, follow instructions given in step 1).

8. The head can now be assembled onto the pump. Tilt the top of the pump head away from the pump slightly until the crescent enters the inside diameter of the rotor and rotate the idler until its teeth mesh with the rotor teeth.

6. If the old metal shims are not reusable or if any parts have been replaced, operating clearances will need to be re-established. Refer to “ADJUSTING END CLEARANCE” on page 13. Otherwise, place the head shims on the head. The proper amount of shims should be used to provide the correct end clearance. Table 7 gives the quantity of shims available in a gasket set along with standard end clearance.

Locknut Torque Requirement

In-Lbs N-m

MD2-B 60 6.8

MD2-C 80 9

TABLE 6

Mark

The pump head and casing should have been marked

before disassembly to insure proper reassembly. If not, be sure the idler pin, which is offset in the pump head, is placed in the 12 o’clock position from the port connections to allow for proper flow of liquid through the pump. Install the head capscrews. Rotate the shaft to make sure it turns freely.

9. Follow the instructions listed for assembling the appropriate size coupling on page 12.

PUMP ROTATION

The pump is designed to operate in either direction. Process fluid is generally fed to the inner thrust washer and bushing interface and then through a groove in the bushing to the outer thrust washer. Then the fluid is pulled into the canister bushing and back through the hollow shaft and idler pin to the suction side of the pump. When the pump is operated in the opposite direction, the fluid flow is reversed.

Leading Edge of

Locknut

FIGURE 16

*Hot water makes the PTFE more pliable and allows the inner elastomer to pull the PTFE back to the orginal size.

FIGURE 17

SECTION TSM 685.2 ISSUE C PAGE 11 OF 16

ASSEMBLY OF COUPLING

Series MD2-B and MD2-C, All Sizes

DANGER !

Follow these directions exactly to avoid injury to self or damage to the pumping unit. Be careful to keep the inner and outer magnets at least (1) foot apart until step 4. Do not engage the magnets in any other fashion.

CAUTION !

Do not place fingers onto the front of pump mounting flange. Align the canister into bore of the bracket and gently slide it in. When the magnets start to engage, the unit will finish engagement on its own very rapidly unless the M10x120mm capscrew is properly used. Make sure fingers are not on the front of the pump. See Figure Sequence 19.

DANGER!

Be certain that the driving means (motor, turbine, engine, etc.) has been “locked out” or made non-operational so that it cannot be started while work is being done on pump.

1. Inspect the magnets for any steel objects, which may be

attached. Remove any foreign material.

MD2-B Couplings:

Mount the outer magnet assembly. Locate the outer magnet assembly per dimension (See Figure 18).

MD2- C Couplings:

Units using a NEMA C-face frame motor will require an adaptor plate. Mount the adaptor plate to the motor if it was removed. Mount the outer magnet assembly. Locate the outer magnet assembly per

dimension (See Figure 18). Apply Loctite® and tighten the setscrews onto the motor or bearing carrier key and shaft.

2. If the bracket is not fastened to a base, clamp it down. Mount the motor or bearing carrier to the bracket. Reach in and rotate the magnets by hand to make sure there is no interference. If rubbing occurs check the dimension in Figure18 or contact the factory.

3. Check to make sure the pump rotates freely by turning the inner magnet assembly. Inspect the magnet to make sure it has not picked up any foreign particles, which could damage the pump. Make sure the canister O-ring is in good condition and in place. Place the canister onto the pump and press on until the canister is in contact with the pump mounting flange.

4. Use a fully threaded M10X120mm capscrew (jackscrew) to guide the canister into the bracket. Thread the capscrew all the way into the bracket as shown in

Figure Sequence 19.

the pump if possible while guiding the canister into the bracket opening.

Use an overhead hoist to support

Carefully back out the capscrew while guiding the canister into the bracket. Secure the pump to the bracket with four 12mm capscrews.

5. Be certain that the power supply to the pump is “Lockedout”. Check that pump rotates freely by spinning the motor fan blades or the bearing carrier shaft.

Dimensions are not the same between designs

Motor

I.E.C. 110/112 7.73 196.4 MM

I.E.C. 132 8.53 216.5 MM 182TC/184TC 8.11 206 MM 213TC/215TC 8.49 215.7 MM 254TC/256TC 9.11 231 MM

NEMA Measured from edge of adaptor plate)

Motor

I.E.C.132 10.43 265 MM

I.E.C.160/180 11.61 295 MM

213TC-256TC 10.43 265 MM

284/286TC 10.43 265 MM

M10X120 CAPSCREW

PUMP AND BRACKET ASSEMBLY SEQUENCE

MD2-B Magnets

(Measured from the motor face)

“A” Dimension

(Inch)

MD2-C Magnets

(I.E.C. Measured from motor face

“A” Dimension

(Inch)

FIGURE 18

DO NOT PLACE FINGERS HERE

4) 12mm Capscrew

FIGURE 19

“A” Dimension (Metric)

DO NOT PLACE FINGERS HER

SECTION TSM 685.2 ISSUE C PAGE 12 OF 16

ADJUSTING END CLEARANCE

Table 7-A provides standard operating end clearance for this pump. Use either of the following procedures to properly adjust the end clearance when replacing shims or reassembling the pump.

PROCEDURE A

After the rotor has been installed and the locknut has been positioned and retained, insert a feeler gage of the proper end clearance thickness into the port at the root (base) of two rotor teeth (See Figure 20). For convenience, remove the head O-ring and install one 0.007” shim onto the head. With the idler on the idler pin, place the head into the pump casing. With the capscrews tight, the feeler gage should fit snugly between the idler and the rotor face; otherwise shims should be added or reduced in thickness until the proper clearance is attained.

PROCEDURE B

If the pump is in line and ports are not accessible, remove the head and shims. Put the head back on (without shims) and measure the gap as shown (See Figure 21). After determining the gap between the head and casing, select a combination of shims equal to the measured gap plus the desired end clearance (See Figure 21). Remove head, install shims then install head. Tighten the head capscrews and check the pump clearance by making sure the pump turns freely by hand. Since the pump shaft is concealed, it is best to work up to the proper end clearance because it is difficult to determine when there is too much end clearance with this approach.

Head end

FIGURE 20

FIGURE 21

END

(inch)

SHIMS INCLUDES

NORMAL

CLEARANCE

AS, AK, AL 855 0.005

KE, KKE 855 0.005

TABLE 7-A

Coupling end

SET OF HEAD

(1) .007 (1) .005 (2) .002 (2) .001

PRESSURE RELIEF VALVE INSTRUCTIONS

DANGER !

engine, etc.) has been “locked out” or made

Before opening any Viking pump liquid chamber (pumping chamber, reservoir, relief valve adjusting cap fitting etc.) Be sure:

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

2. That the driving means (motor, turbine,

non- operational so that it cannot be started while work is being done on 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.

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

SECTION TSM 685.2 ISSUE C PAGE 13 OF 16

DISASSEMBLY – RELIEF VALVE

Mark the valve and head before disassembly to insure proper reassembly.

1. Remove the valve cap.

DANGER!

Before starting pump, be sure all drive equipment guards are in place.

2. Measure and record the length of extension of the adjusting screw. Refer to “A” on Figure 22.

3. Loosen the locknut and back out the adjusting screw

until spring pressure is released.

4. Remove the bonnet, spring guide, spring and poppet from the valve body. Clean and inspect all parts for wear or damage and replace as necessary.

ASSEMBLY – RELIEF VALVE

Reverse the procedures outlined under DISASSEMBLY – RELIEF VALVE.

to replace in the original position. The relief valve adjusting screw cap must always point towards the suction side of the pump. If the pump rotation is reversed, remove the relief valve and turn end for end. Refer to Figure 3, page 3.

If the valve is removed for repairs, be sure

Failure to properly mount guards may result in serious injury or death.

PRESSURE ADJUSTMENT

If a new spring is installed or if the pressure setting of the pressure relief valve is to be changed from that which the factory has set, the following instructions must be carefully followed.

1. Carefully remove the valve cap, which covers the adjusting screw.

2. Loosen the locknut, which locks the adjusting screw so

pressure setting will not change during operation of pump.

3. Install a pressure gauge in the discharge line for the actual adjustment operation.

4. Turn the adjusting screw in to increase pressure and out to decrease pressure.

5. With discharge line closed at a point beyond the pressure gauge, gauge will show the maximum pressure valve will allow while the pump is in operation.

IMPORTANT

FIGURE 22

VALVE – AS, AK, AL, KE AND KKE SIZES

VALVE - LIST OF PARTS

1. Valve Cap

2. Adjusting Screw 7. Valve Spring

3. Lock Nut 8. Poppet

4. Spring Guide 9. Cap Gasket

5. Bonnet

6. Valve Body

TABLE 8

When ordering parts for the pressure relief valve, always give the model number and serial number of the pump as it appears on nameplate and name of the part wanted. When ordering springs, be sure to give pressure setting desired.

SECTION TSM 685.2 ISSUE C PAGE 14 OF 16

TROUBLESHOOTING

Some of the following may help pinpoint the problem:

Pump does not pump:

• Pump has lost its prime from air leak or low level in tank.

• Suction lift is too high.

• Pump is rotating in the wrong direction.

• The strainer may be clogged.

• The bypass valve is open, the pressure relief valve is set too low or the pressure relief valve poppet is stuck open.

• Improper end clearance.

• The pump is worn out.

• Are there any changes in liquid, system or operation that would influence pump or coupling performance, e.g. new liquid, additional lines or process changes?

• Temperature changes either in the liquid or the environment.

• The magnetic coupling is decoupling. Changes in application (temperature, pressure, viscosity, etc.) may require torque beyond coupling capabilities.

Pump starts, then loses its prime:

• The supply tank is empty.

• Liquid is vaporizing in the suction line.

• An air leak or air pocket in the suction line.

Pump is not delivering up to capacity:

• The pump is starving or cavitating - increase suction pipe size or reduce length or reduce pump speed.

• The strainer is partially clogged.

• An air leak somewhere in suction line.

• The pump may be running too slow. Is motor the correct speed and wired up correctly ?

• The pressure relief valve is set too low, stuck open or has a damaged poppet or seat.

• The bypass line around the pump is partially open.

• The pump is worn out or there is too much end clearance.

Pump takes too much power (stalls motor):

• The liquid is more viscous than the unit is sized to handle.

• The system pressure relief valve is set too high.

• The bushings have frozen up or the liquid has set up in the pump.

Pump is noisy:

• The pump is being starved (viscous liquid cannot get to pump fast enough). Increase the suction pipe size, reduce its length or slow down the pump.

• The pump is cavitating (liquid vaporizing in suction line). Increase suction pipe size or reduce its length.

• Check alignment.

• The magnetic coupling has decoupled. Shut off and restart.

SECTION TSM 685.2 ISSUE C PAGE 15 OF 16

TECHNICAL SERVICE MANUAL

SERIES 855

Sizes AS, AK, AL, KE, KKE

WARRANTY

Viking warrants all products manufactured by it to be free from defects in workmanship or material for a period of one (1) year from date of startup, provided that in no event shall this warranty extend more than eighteen (18) months from the date of shipment from Viking. If, during said warranty period, any products sold by Viking prove to be defective in workmanship or material under normal use and service, and if such products are returned to Viking’s factory at Cedar Falls, Iowa, transportation charges prepaid, and if the products are found by Viking to be defective in workmanship or material, they will be replaced or repaired free of charge, FOB. Cedar Falls, Iowa.

Viking assumes no liability for consequential damages of any kind and the purchaser by acceptance of delivery assumes all liability for the consequences of the use or misuse of Viking products by the purchaser, his employees or others. Viking will assume no field expense for service or parts unless authorized by it in advance.

Equipment and accessories purchased by Viking from outside sources which are incorporated into any Viking product are warranted only to the extent of and by the original manufacturer’s warranty or guarantee, if any.

THIS IS VIKING’S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, WHICH ARE HEREBY EXCLUDED, INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No officer or employee of IDEX Corporation or Viking Pump, Inc. is authorized to alter this warranty.

SECTION TSM

PAGE

ISSUE

16 OF 16

685.2

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

Viking MAG DRIVE 855 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual