Viking pump G4195, GG4195, AS4195, H4195, AK4195 Service Manual
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Electronic copies of the most current TSM issue can be found on the Viking Pump website at www.vikingpump.com
TECHNICAL SERVICE MANUAL
SIZES G, GG, H, HJ, HL, AS, AK, AL
CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Information....................2
Special Information . . . . . . . . . . . . . . . . . . . 3
Special Mechanical Seals................3
Maintenance . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7
Thrust Bearing Adjustment . . . . . . . . . . . . . . . 8
Installation of Carbon Graphite Bushings ........8
Pressure Relief Valve Instructions . . . . . . . . . . . 9
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 complete name of part, part number and material with
model number and serial number of pump when ordering
repair parts. The unmounted pump or pump unit model
number and serial number are on the nameplate.
SECTION TSM 144
HEAVY-DUTY PUMPS
SERIES 4195 AND 495
PAGE 1 OF 10
ISSUE F
FIGURE 1
G, GG, H, HJ and HL4195 SERIES
Foot Type Unmounted Pump with Tapped Ports
In the Viking model number system, basic size letters are
combined with series number (4195 and 495) are used to
indicate either an unmounted pump or mounted pump unit.
UNMOUNTED PUMP UNITS
Foot Mounted
G4195 HL4195
GG4195 AS4195
H4195 AK4195
HJ4195 AL4195
Flange Mounted
G495 HL495
GG495 AS495
H495 AK495
HJ495 AL495
This manual deals only with Series 4195 and 495 Heavy
Duty Pumps. Refer to Figures 1 through 14 for general
configuration and nomenclature used in this manual. Pump
specifications and recommendations are listed in Catalog
Section 144, Series 4195 and 495 Heavy Duty Pumps.
Units are designated by the
unmounted pump model
numbers followed by a letter(s)
indicating drive style.
D = Direct Drive
M = Horizontal Direct Drive
FIGURE 2
AS, AK and AL4195 SERIES
Foot Type Unmounted Pump with Tapped Ports
FIGURE 3
G, GG, H, HJ and HL495 SERIES
Unmounted Pump with Tapped Ports
FIGURE 4
AS, AK and AL495 SERIES
Unmounted Pump with Tapped Ports
VIKING PUMP, INC. x A Unit of IDEX Corporation xCedar 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
!
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 :
Ɣ Any pressure in the chamber has been completely
vented through the suction or discharge lines or
other appropriate openings or connections.
Ɣ 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.
Ɣ 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 operating the pump, be sure all drive guards
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 operating the pump, be sure that:
Ɣ It is clean and free from debris
Ɣ all valves in the suction and discharge pipelines
are fully opened.
Ɣ All piping connected to the pump is fully supported
and correctly aligned with the pump.
Ɣ 3ump rotation is correct for the desired direction
of flow.
WARNING
WARNING
!
WARNING
!
!
!
WARNING
!
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 144 ISSUE F PAGE 2 OF 10
SPECIAL INFORMATION
DANGER !
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.
ROTATION: Viking pumps operate equally well in a clockwise
or counterclockwise rotation. Shaft rotation determines which
port is suction and which is discharge. Suction Port is where
pumping elements (gear teeth) come out of mesh.
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.
2. There are relief valve options available on those pump
models designed to accept a relief valve. Options may
include a return to tank relief valve. Pumps equipped
with a jacketed head plate are generally not available
with a relief valve.
3. If pump rotation is 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. If pump rotation is
reversed, remove the pressure relief valve and turn end
for end. Refer to Figure 5.
5. Pressure relief valves should not be used to control flow
or regulate discharge pressure.
For additional information on pressure relief valves, refer
to Technical Service Manual TSM 000 and Engineering
Service Bulletin ESB-31.
SPECIAL MECHANICAL SEALS:
This bulletin illustrates the mechanical seal which is
standard in the catalog pump. A Seal Installation Drawing
will be furnished with a pump fitted with a non-standard
mechanical seal. Consult this Seal Installation Drawing
before disassembling pump.
Modifications are required to install PTFE mechanical seals
in these pumps. Contact the factory for specific information.
RELIEF VALVE ADJUSTING SCREW CAP
SUCTION
FIGURE 5
DISCHARGE
MAINTENANCE
Series 4195 and 495 pumps are designed for long, troublefree 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
and help prevent overlooking a dirt covered grease fitting.
STORAGE: If the pump is to be stored, or not used for six
months or more, the pump must be drained and a light coat of
non-detergent SAE 30 weight oil must be applied to all internal
pump parts. Lubricate the fittings and apply grease to the pump
shaft extension. Viking suggests rotating pump shaft by hand
one complete revolution every 30 days to circulate the oil.
SUGGESTED REPAIR TOOLS: The following tools must
be available to properly repair Series 4195 and 495 pumps.
These tools are in addition to standard mechanics’ tools such
as open end wrenches, pliers, screw drivers, etc. Most of the
items can be obtained from an industrial supply house.
1. Soft Headed hammer
2. Allen wrenches (set screws & special mechanical seals)
3. Snap Ring Pliers
INTERNAL – Viking Part No. 2-810-047-999
G-GG-H-HJ-HL 4195-495
EXTERNAL – Viking Part No. 2-810-029-375
G-GG-H-HJ-HL 4195-495
4. Mechanical Seal Installation Sleeve
2-751-001-730 for 0.75 inch seal; G-GG 4195-495
2-751-004-730 for 1.25 inch seal; AS-AL 4195-495
5. Bearing Locknut Spanner Wrench – 2-810-043-375
6. Spanner Wrench, adjustable pin type for use on bearing
housing end cap. – 2-810-008-375
7. Brass bar
8. Arbor press
9. Standard 5/16” 12 point socket
SECTION TSM 144 ISSUE F PAGE 3 OF 10
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