Viking Pump TSM144 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

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 H

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. • 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

!

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 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:

● 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.

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 H 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. 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 H PAGE 3 OF 10

DISASSEMBLY

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.

1. Refer to Figures 7 & 8, page 5 for model to be

disassembled and name of parts. Models 4195 & 495
are disassembled and assembled in the same manner.
The difference between these models is the casings.

2. Mark the head and casing before disassembly to insure
proper reassembly.

3. NOTE: The four valve capscrews, valve and gasket must
be removed from the G-GG 4195-495 model before the
six head capscrews are removed.

Remove the head capscrews.

4. Tilt the top of the head back when removing to prevent
the idler from falling off the idler pin.

5. Remove the idler and bushing assembly. If the idler
bushing needs replacing, see “Installation of Carbon

Graphite Bushings,” page 8.

6. Insert a brass bar or piece of hardwood in the port

opening and between the rotor teeth to keep the shaft
from turning. Turn the locknut counterclockwise and
remove locknut. See Figure 9 or 10, page 6.

7. Loosen the two setscrews in the face of the bearing
housing and turn the thrust bearing assembly
counterclockwise and remove from casing. See Figure

9 or 10, page 6.

8. H, HJ, HL: Remove the snap ring from the shaft.
See Figure 9, page 6.

AS, AK, AL: Remove the bearing spacer from the shaft.
See Figure 10, page 6.

9. Remove the brass bar or piece of hardwood from the

port opening.

PRESSURE RELIEF VALVE

IDLER PIN

HEAD

IDLER

HEAD GASKET

CUTAWAY FOR MODELS G, GG, H, HJ AND HL4195

ROTOR

FIGURE 6

MECHANICAL SEAL

CASING

BALL BEARINGS

SHAFT

SNAP RINGS

SECTION TSM 144 ISSUE H PAGE 4 OF 10

CASING

Modifications to the pump casing and rotor are required for installation
of optional PTFE mechanical seal. Consult the factory.

FIGURE 7 - EXPLODED VIEW FOR MODELS G, GG, H, HJ AND HL 4195 AND 495

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

1 Locknut 8 Casing (4195) 14 Head O-Ring

2 Snap Ring (Outer) 8A Casing (495) 15 Idler Pin

3 Ball Bearing (Outer) 9 Pipe Plug 16 Head and Idler Pin Assembly

4 Snap Ring for Shaft * 10 Mechanical Seal 17 Capscrew for Head

5 Bearing Housing 11 Rotor and Shaft Assembly 18 Gasket for Relief Valve

6 Snap Ring (Inner) 12 Idler Bushing 19 Relief Valve

7 Ball Bearing (Inner) 13 Idler and Bushing Assembly 20 Capscrew for Valve

* Not used on G & GG size pumps.

Modifications to the pump casing and rotor are required for installation
of optional PTFE mechanical seal. Consult the factory.

FIGURE 8 - EXPLODED VIEW FOR MODELS AS, AK AND AL 4195 AND 495

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

1 Locknut 9 Bearing Retainer Washer 16 Mechanical Seal

2 Bearing Spacer Collar 10 Casing (4195) 17 Idler Bushing

3 End Cap for Bearing Housing 10A Casing (495) 18 Idler and Bushing Assembly

4 Lip Seal for Bearing Housing 11 O-Rings for Relief Valve 19 Head O-Ring

5 Ball Bearing (Outer) 12 Relief Valve 20 Idler Pin

6 Bearing Housing 13 Pipe Plug 21 Check Valve

7 Bearing Spacer 14 Capscrew for Valve 22 Head and Idler Pin Assembly

8 Ball Bearing (Inner) 15 Rotor and Shaft Assembly 23 Capscrew for Head

SECTION TSM 144 ISSUE H PAGE 5 OF 10

OUTER BALL BEARING

OUTER SNAP RING

LOCKNUT

INNER BALL BEARING

INNER SNAP RING

SHAFT

SHAFT SNAP RING*

BEARING HOUSING

SETSCREW

FIGURE 9 - THRUST BEARING ASSEMBLY G, GG, H, HJ AND HL SIZES

BALL BEARING

SETSCREW

BEARING RETAINER WASHER

INNER BALL BEARING

NYLON INSERT

END CAP
LIP SEAL

SHAFT

BEARING SPACER

LOCKNUT

BEARING SPACER COLLAR

BEARING HOUSING

SETSCREW

* NOT USED ON
G & GG SIZE PUMPS

FIGURE 10 - THRUST BEARING ASSEMBLY AS, AK AND AL SIZES

10. The rotor and shaft can now be removed by tapping on

the end of the shaft with a lead hammer or, if using a
regular hammer, use a piece of hardwood between the
shaft and hammer. The rotary member of the seal will
come out with the rotor and shaft.

11. AS, AK, AL: Remove the bearing retainer washer. The
washer may have stayed with the rotor and
shaft when removed or is against the ball
bearing. See Figure 10.

12. Remove the mechanical seal rotary member and spring

from the rotor and shaft assembly.

13. G, GG, H, HJ, HL: Remove the inner snap ring and

single row ball bearing from the casing.

AS, AK, AL: Remove the single row ball bearing from

the casing.

14. Remove the seal seat or stationary part of the seal from

the casing.

SECTION TSM 144 ISSUE H PAGE 6 OF 10

15. Disassemble the thrust bearing assembly.

G, GG, H, HJ, HL: Remove the outer snap ring from

the bearing housing and remove the
ball bearing. See Figure 9.

AS, AK, AL: Loosen the two setscrews in the flange

outside diameter. Rotate the end cap and
lip seal counterclockwise and remove.
Remove the ball bearing. See Figure 10.

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

When making major repairs, such as replacing a rotor and
shaft; it is advisable to also install a new mechanical seal,
head and idler pin, idler and bushing. See “Installation of
Carbon Graphite Bushings,” page 8.

Clean all parts thoroughly and examine for wear or damage.
Check the lip seals, ball bearings, bushing and idler pin and
replace if necessary. Check all other parts for nicks, burrs,
excessive wear and replace if necessary.

Check the bearings for roughness. Roughness can be
determined by turning the outer race by hand. Replace the
bearings if they have roughness.

Be sure the shaft is free from nicks, burrs and foreign
particles that might damage the mechanical seal. Scratches
on the shaft in seal area will provide leakage paths under the
mechanical seal. Use a fine emery cloth to remove scratches
or sharp edges.

SPRING

COAT WITH LIGHT OIL BEFORE ASSEMBLY

MECHANICAL SEAL
(ROTARY MEMBER)

TAPERED SLEEVE

FIGURE 11

ASSEMBLY

Standard Mechanical Seal
(Synthetic Rubber Bellows Type)

READ CAREFULLY BEFORE REASSEMBLING PUMP

The seal used in this pump is simple to install and good
performance will result if care is taken during installation.

The principle of a mechanical seal is contact between the
rotary and stationary members. These parts are lapped to
a high finish and their sealing effectiveness depends on
complete contact.

Prior to installing the rotary portion of the mechanical
seal, prepare and organize the rotor shaft, head and idler
assemblies and appropriate gaskets for quick assembly.

Once the rotary portion of the mechanical seal is installed
on the rotor shaft, it is necessary to assemble the parts as
quickly as possible to insure the seal does not stick to the
shaft in the wrong axial position. The seat will stick to the
shaft after several minutes setting time.

Never touch the sealing faces with anything except clean
hands or clean cloth. Minute particles can scratch the seal
faces and cause leakage.

1. Coat the idler pin with non-detergent SAE 30 weight
oil and place idler and bushing on idler pin in the
head. If replacing a carbon graphite bushing, refer to

“Installation of Carbon Graphite Bushings,” page 8.

2. Clean the rotor hub and casing seal housing bore. Make

sure both are free from dirt and grit. Coat the outer
diameter of seal seat and inner diameter of seal housing
bore with non-detergent SAE 30 weight oil.

3. Start the seal seat in the seal housing bore. If force is
necessary protect the seal face with a clean cardboard
disc and gently tap it in place with a piece of wood. Be
sure the seal seat is completely seated in the bore.

4. Place a tapered installation sleeve on the shaft, refer to
Figure 11. The sleeve is furnished with G, GG, AS, AK

and AL replacement mechanical seals. Coat the rotor
shaft, tapered installation sleeve and inner diameter of
the mechanical seal rotary member with a generous
amount of non-detergent SAE 30 weight oil. Petrolatum
may be used but grease is not recommended.

5. Place the seal spring on the shaft against the rotor hub.
Refer to Figure 12.

6. Slide the rotary member, lapped contact surface facing
away from the spring, over installation sleeve on shaft
until just contacting the spring. Do not compress the
spring. Remove the installation sleeve.

ROTOR HUB

SPRING

SHAFT

MECHANICAL SEAL
(ROTARY MEMBER)

FIGURE 12

7. Coat the rotor shaft with non-detergent SAE 30 weight

oil. Install the rotor and shaft into the casing, slowly
pushing until the ends of the rotor teeth are just below
the face of the casing. Take care not to damage the seal
seat.

8. Leave the rotor in this position. Withdrawal of the rotor
and shaft may displace the carbon seal rotating face and
result in damage to the seal.

9. Place the O-ring or gasket on the head and install the
head and idler assembly on pump. The pump head
and casing were marked before disassembly to insure
proper reassembly. If not, be sure the idler pin, which
is offset in the pump head, is positioned up and equal
distance between port connections to allow for proper
flow of liquid through the pump.

10. Tighten the head capscrews evenly.

11. If the pump was equipped with a relief valve and was

removed during disassembly, install on the head with
new O-Rings or gaskets. The relief valve adjusting screw
cap must always point towards the suction port. Refer to
Figure 5, page 3. For relief valve repair or adjustments,
see “Pressure Relief Valve Instructions,” Page 9.

12. In 2005, the use of single seal bearings were phased
out. Pumps now use “Sealed for Life” bearings that
have seals on both sides. The new bearings can be
installed either side first and do not need to be packed
with grease. For older models with single seal bearings,
pack the inner ball bearing with multi-purpose grease,
NLGI #2.

SECTION TSM 144 ISSUE H PAGE 7 OF 10

G, GG, H, HJ, HL: Drive the bearing into the bore. Tap

the inner race with a brass bar and
lead hammer to position bearing.
Install the inner snap ring.

AS, AK, AL: Install the bearing retainer washer over

the shaft before installing the ball bearing.
Install the ball bearing in the casing. Drive
the bearing into the bore. Tap the inner
race with a brass bar and lead hammer to
position the bearing.

13. H, HJ, HL: Install the shaft snap ring in groove in
the shaft. See Figure 9, page 6.

AS, AK, AL: Install the bearing spacer over the shaft

and against the single row ball bearing.
See Figure 10, page 6.

14. G, GG, H, HJ, HL: Install the ball bearing into the bearing
housing See Figure 9, page 6. Install
the snap ring into bearing housing to
retain ball bearing. This snap ring has
a tapered edge to fit tapered groove in
bearing housing. The tapered edge is
located away from the ball bearing.

AS, AK, AL: Install the ball bearing into the bearing

housing. Install the lip seal in the bearing
housing end cap. The lip should face
towards the end of the shaft. Put the bearing
spacer collar in the lip seal and install in
the bearing housing and tighten the set
screws securely. See Figure 10, page 6.

15. Insert a brass bar or piece of hardwood through the port
opening between the rotor teeth to keep the shaft from
turning.

16. Start the thrust bearing assembly into casing. Turn by
hand until tight. This forces the rotor against the head.
Replace and tighten the locknut on shaft.

17. Remove the brass bar or hardwood from port opening.

18. Adjust pump end clearance, refer to “Thrust Bearing
Adjustment”.

THRUST BEARING ADJUSTMENT

See Figures 9 and 10.

Loosen the two screws in the face of the thrust bearing
assembly.

If the shaft cannot be rotated freely, turn the thrust bearing
assembly counterclockwise until the shaft can be turned
easily.

To set end clearance:

1. While turning the rotor shaft, rotate the thrust bearing
assembly clockwise until a noticeable drag occurs. This
is zero end clearance.

2. Mark the position of the bearing housing with respect to
the casing.

3. Rotate the thrust bearing assembly counterclockwise the
distance listed below as measured on outside of bearing
housing.

4. After the adjustment is made, tighten the two setscrews
in the face of the bearing housing assembly to secure
the position.

For viscosities above 2500 SSU, add additional end

clearance (0.004” for G, GG, H, HJ and HL size pumps
and 0.005” for AS, AK and AL size pumps).

PUMP

SIZE

G, GG 0.44” (7/16”) .003

H, HJ , HL 0.56” (9/16”) .003

AS , AK , AL 0.5” (1/2”) .003

DISTANCE IN INCHES
ON O.D. OF BEARING

HOUSING

STANDARD

END

CLEARANCE

DANGER !

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

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

SECTION TSM 144 ISSUE H PAGE 8 OF 10

INSTALLATION OF CARBON
GRAPHITE BUSHINGS

When installing the carbon graphite bushings, extreme care
must be taken to prevent breaking. Carbon graphite is a brittle
material and is easily cracked. If cracked, the bushing will
quickly disintegrate. Using a lubricant and adding a chamfer
on the bushing and the mating part will help in installation.
The additional precautions listed below must be followed for
proper installation:

1. A press must be used for installation.

2. Be certain the bushing is started straight.

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

the proper position, as starting and stopping may result
in a cracked bushing.

4. Check the bushing for cracks after installation.

PRESSURE RELIEF VALVE
INSTRUCTIONS

FIGURE 13

VALVE - G, GG, H, HJ and HL SIZES

VALVE - LIST OF PARTS

1. Valve Cap 6. Valve Body

2. Adjusting Screw 7. Valve Spring

3. Lock Nut 8. Poppet

4. Spring Guide 9. Cap Gasket

5. Bonnet

DISASSEMBLY

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.

FIGURE 14

VALVE - AS, AK and AL SIZES

VALVE - LIST OF PARTS

1. Valve Cap 6. Valve Body

2. Adjusting Screw 7. Valve Spring

3. Lock Nut 8. Poppet

4. Spring Guide 9. Cap Gasket

5. Bonnet 10. Bonnet O-Ring

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

1. Remove the valve cap.

2. Measure and record the length of extension of the
adjusting screw. Refer to “A” on Figures 13 and 14.

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

Reverse the procedures outlined under “Disassembly.” If
the valve is removed for repairs, be sure to replace in the
same position. The relief valve adjusting screw cap must
always point towards suction side of the pump. If the pump
rotation is reversed, remove the relief valve and turn end for
end. Refer to Figure 5, page 3.

SECTION TSM 144 ISSUE H PAGE 9 OF 10

TECHNICAL SERVICE MANUAL

SIZES G, GG, H, HJ, HL, AS, AK, AL

DANGER !

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

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.

Loosen the locknut which locks the adjusting screw so
the pressure setting will not change during operation of
the pump.

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

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

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

IMPORTANT

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

SECTION TSM 144

HEAVY-DUTY PUMPS

SERIES 4195 AND 495

PAGE 10 OF 10

ISSUE H

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. The warranty period for Universal Seal series
pumps ONLY (Universal Seal models listed below) is
three (3) years from date of startup, provided that in
no event shall this warranty extend more than forty-two
(42) months from the date of shipment from Viking.

UNDER NO CIRCUMSTANCES SHALL VIKING BE
LIABLE UNDER THIS WARRANTY OR OTHERWISE
FOR SPECIAL, INCIDENTAL, INDIRECT,
CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY
KIND, INCLUDING, BUT NOT LIMITED TO, LOST
OR UNREALIZED SALES, REVENUES, PROFITS,
INCOME, COST SAVINGS OR BUSINESS, LOST OR
UNREALIZED CONTRACTS, LOSS OF GOODWILL,
DAMAGE TO REPUTATION, LOSS OF PROPERTY,
LOSS OF INFORMATION OR DATA, LOSS OF
PRODUCTION, DOWNTIME, OR INCREASED
COSTS, IN CONNECTION WITH ANY PRODUCT,
EVEN IF VIKING HAS BEEN ADVISED OR PLACED
ON NOTICE OF THE POSSIBILITY OF SUCH
DAMAGES AND NOTWITHSTANDING THE FAILURE
OF ANY ESSENTIAL PURPOSE OF ANY PRODUCT.

THIS WARRANTY IS AND SHALL BE VIKING’S SOLE
AND EXCLUSIVE WARRANTY AND SHALL BE IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING, BUT NOT LIMITED
TO, ALL WARRANTIES OF MERCHANTABILITY,
FITNESS FOR A PARTICULAR PURPOSE AND
NON-INFRINGEMENT ALL OF WHICH OTHER
WARRANTIES ARE EXPRESSLY EXCLUDED.

See complete warranty at www.vikingpump.com.

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

© 8/2014 Viking Pump Inc.
All rights reserved