Viking Pump TSM280 User Manual

INSTALLATION, OPERATION

AND

MAINTENANCE MANUAL

FOR THE

VIKING PUMP, INC. A Unit of IDEX Corporation
Cedar Falls, Iowa 50613 U.S.A.

Issue B - Jun 03

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FOR DURALOBE® ROTARY LOBE PUMPS.

1.0 SAFETY INFORMATION. _______________________________________ 3

RISK ASSESSMENT RELATING TO THE USE OF VIKING PUMP DURALOBE ROTARY LOBE

PUMPS AND PUMP UNITS IN POTENTIALLY EXPLOSIVE ATMOSPHERES

. ______________ 6

2.0 INTRODUCTION. ______________________________________________ 7

2.1 GENERAL. ___________________________________________________ 7

2.2 VIKING PUMP DISTRIBUTORS. _____________________________________ 7

2.3 RECEIPT AND STORAGE._________________________________________ 7

2.4 CLEANING. __________________________________________________ 8

2.5 PUMP MODEL DESIGNATION. _____________________________________ 8

2.5.1 A

2.5.2 E

TEX INFORMATION PLATE _____________________________________ 9
QUIPMENT GROUPS & CATERGORIES_____________________________ 9

2.6 PUMP MODEL AND SERIAL NUMBER. _______________________________ 10

2.7 STANDARD PUMP COMPONENT TERMS._____________________________ 11

3.0 GENERAL. __________________________________________________ 12

3.1 DURALOBE

3.2 DURALOBE

®

PUMPING PRINCIPLE._________________________________ 12

®

PUMP OPERATING PARAMETERS. ________________________ 13

3.3 SYSTEM DESIGN. _____________________________________________ 14

3.3.1 SYSTEM DESIGN AND INSTALLATION. _____________________________ 14

3.3.2 INSTALLATIONS WITH CIP SYSTEMS. _____________________________ 16

3.4 START UP PROCEDURE.________________________________________ 16

3.6 ROUTINE MAINTENANCE. _______________________________________ 18

3.7 HEATING AND COOLING DEVICES _________________________________ 18

3.8 INTEGRAL PRESSURE RELIEF VALVES ______________________________ 21

3.8.1 SETTING AND OPERATING SPRING LOADED VALVES __________________ 22

3.8.2 SETTING AND OPERATING AIR LOADED VALVE ______________________ 23

4.0 DURALOBE® PUMP DISMANTLING AND ASSEMBLY. ______________ 30

4.1 DISASSEMBLY._______________________________________________ 31

4.1.2 C

ARTRIDGE REMOVAL _______________________________________ 33

4.1.3 CARTRIDGE DISASSEMBLY ____________________________________ 34

4.2 ASSEMBLY. _________________________________________________ 35

4.2.1 C

ARTRIDGE ASSEMBLY _______________________________________ 35

4.2.2 CARTRIDGE TO ROTORCASE ASSEMBLY___________________________ 39

4.2.3 ROTOR ASSEMBLY AND SETTING ROTOR CLEARANCES________________ 41

4.2.4 GEARBOX COVER ASSEMBLY __________________________________ 43

4.3 PRODUCT SEAL FITTING AND REMOVAL. ____________________________ 44

4.3.1 GENERAL PROCEDURES FOR FITTING MECHANICAL SEALS._____________ 44

4.3.2 SINGLE MECHANICAL SEAL ____________________________________ 45

4.3.3 SINGLE FLUSHED MECHANICAL SEAL_____________________________ 47

4.3.4 DOUBLE MECHANICAL SEAL ___________________________________ 49

4.3.5

4.3.6 D

SINGLE O-RING SEAL________________________________________ 51

OUBLE O-RING SEAL _______________________________________ 52

4.3.7 TRAPPED SLEEVE___________________________________________ 53

4.3.8 HYBRID DOUBLE MECHANICAL 2000 SEAL _________________________ 54

Page : 1

4.3.9 HYBRID DOUBLE MECHANICAL SEAL _____________________________ 55

4.3.10 HYBRID SINGLE FLUSHED MECHANICAL SEAL_______________________ 56

4.3.11 STRIP CLEAN SINGLE O-RING SEAL ______________________________ 57

4.3.12 DURALOBE SINGLE O-RING SEAL OL1____________________________ 58

4.3.13 DURALOBE SINGLE O-RING SEAL S2, S3, S4_______________________ 59

4.3.14 MK2 DOUBLE O-RING SEAL S1_________________________________ 60

4.3.15 MK2 DOUBLE O-RING SEAL S2, S3, S4 __________________________ 61

4.3.16 FLUSHED PRODUCT SEAL _____________________________________ 62

5.0 SPECIFICATIONS.____________________________________________ 65

5.1 CLEARANCE CHART ___________________________________________ 65

5.2 FASTENERS & TORQUE SETTINGS. ________________________________ 66

5.3 L

5.4

UBRICANTS ________________________________________________ 67

MATERIAL SPECIFICATION. ________________________________________ 67

Page : 2

1.0 Safety Information.

WARNING

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.

Danger - Failure to follow the listed
precautionary measures may result
in serious injury or death are
identified by the following symbol:

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 the sign:

WARNING

DANGER

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 gearbox 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. Running
the pump outside of its operating envelope can cause mechanical contact in
the pump head, excessive heat and can represent a serious risk to health and
safety.

Installation and operation of the pump must always comply with health and
safety regulations.

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, (refer to
section 3.8).

Page : 3

The mounting of the pump or pump unit should be solid and stable.

WARNING

WARNING

WARNING

WARNING

WARNING

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 side
loading of the drive shaft. It may also be necessary to earth the pump
to avoid the build up of a potential charge difference that could cause a
spark.

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

Fill all gearboxes with the recommended grades and quantities of lubricant,
(refer to section 3.4). Beware of over / under filling the gearbox as this could
cause the pump to over heat and mechanical damage to occur.

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. This
could result in unexpected mechanical contact in the pump head and has the
potential to be a source of ignition.

Be sure that pump rotation is correct for the desired direction of flow, (refer to
section 3.4).

Do not install the pump into a system where it will run dry (i.e. without a
supply of pumped media) unless it is equipped with a flushed shaft seal
arrangement complete with a fully operational flushing system. Mechanical
seals require a thin fluid film to lubricate the seal faces. Dry running can cause
excessive heat and seal failure.

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 base plate. If pump is base plate
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 section 5.5.

Page : 4

DO NOT attempt to dismantle a pressure relief valve which has not

WARNING

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, pneumatic 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.

had the spring pressure relieved, is still connected to a pressurized
gas/air supply 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. Typical noise emission data can be found in
section 5.8.

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

When cleaning, either manually or by CIP method, the operator must ensure
that a suitable procedure is used in accordance with the system requirements.
During a CIP cleaning cycle, a pump differential pressure of between 30 and
45 psi is recommended to ensure suitable velocities are reached within the
pump head. The exterior of the pump should be cleaned periodically.

Page : 5

Risk assessment relating to the use of Viking Pump Duralobe rotary lobe pumps and

p

g

g

y

p

pump units in potentially explosive atmospheres.

Note:- For a feature to be suitable for an application, The feature must be fit for its

designated purpose and also suitable for the environment where it is to be installed.

Source Of Hazards Potential Hazards

Unvented cavities Build up of explosive gas

Rotorcase / Rotors / Front

Cover

Pump external surfaces

Cover 'O' ring

Pump casing / cover

Shaft seals

Auxiliary system for shaft

sealing

Rotation direction test Excess temperature

Closed valve condition

Shaft Random induced current

Mechanical shaft coupling

(Torque Protection)

Mechanical shaft coupling

(standard)

Unintended mechanical

contact

excess temperature.

Electrostatic charging

Pump liquid leakage. Build

up of explosive gas.

Pump liquid leakage. Build

up of explosive

excess temperature.

Unintended mechanical

contact.

Leakage.

Build up of explosive

Pump liquid leakage. Build

up of explosive gas.

Excess Temperature.

Excess Pressure.

Mechanical contact.

Temperature from friction

Sparks from break up of

shear pins.

Electrostatic charging

Break up of spider.

Unintended mechanical

contact.

Electrostatic charging

as.

as.

Frequency Of

Hazards

Very Rare

Rare

Rare

Very Rare

Very Rare

Rare

Rare

Very Rare

Rare

Very Rare

Rare

Rare

Recommended Measures

Ensure that pump is totally filled.

Consider mounting ports vertically.

See Chapter 1.0

Ensure that operating pressures are

not exceeded. Ensure that suffcient

NPSH to prevent cavitation.

Chapter 1.0/3.3.1

User must ensure temperature limits.

Do not overfill gearboxes with

lubricant. Provide a ground contact

for pump.

Check selection of elastomers are

suitable for application. Ensure cover

retaining nuts are tight. Service plan.

Stainless steel, Corrosion resistant.

Selection of seal system must be

suitable for application.

5.0

Selection of auxiliary seal system

must be suitable for application.

Mechanical seals must never run

If flushed seals are installed ensure

assemblys. Only allow pump to run

for minimum period - just a few

Can cause excessive pressue, heat

Provide a ground contact for pump.

See Chapter 1.0 /

. Service plan. Mechanical seals

must never run dry

that flush is applied to seal

seconds.

and mechanical contact.

Cha

See Chapter 1.0.

Coupling selection must suit

application.

Coupling selection must suit

application. Service plan.

Chapter 1.0.

Service plan.

lan.

.

dr

ter 1.0

See Chapter 1.0.

See

Service

See Chapter

See

See

Page : 6

2.0 Introduction.

2.1 General.

Duralobe® rotary lobe pumps are manufactured by Johnson Pump (UK)

a unit of Viking Pump Inc., Cedar Falls, USA, herein after referred to as
Viking Pump.

This manual includes all the necessary information for Duralobe

®

pumps and should be read prior to beginning installation, operation or
maintenance.

Should you require any additional information regarding the Duralobe®

pumps contact Viking Pump or their local authorized distributor, refer to
section 2.2.

When asking for assistance please provide the pump model and serial

number. This information can be obtained from the pump nameplate
which is located on the side of the pump gearbox cover, refer to section

2.6.

Should the nameplate be unreadable or missing, the pump serial

number is also stamped on either side of the rotorcase, refer to section

2.6.

If the system or product characteristics are to be changed from the

original application for which the pump was selected, Viking Pump or
their authorized distributor should be consulted to ensure the pump is
suitable for the new application.

2.2 Viking Pump Distributors.

Viking Pump distributes it’s products internationally via a network of

authorized distributors. Throughout this manual where reference is
made to Viking Pump, service and assistance will also be provided by
any Viking Pump authorized distributor for Duralobe® pumps.

2.3 Receipt and Storage.

Upon receipt of the pump, immediately examine it for any signs of

visible damage. If any damage is noted, contact Viking Pump or your
Viking Pump distributor and clearly mark upon the carriers paperwork
that the goods have been received in a damaged condition, with a brief
description of damage.

If the pump is not required for immediate installation then it should be
stored in a clean, dry environment. It is recommended that storage
temperature should be between 14°F and 105°F.

Page : 7

2.4 Cleaning.

The Duralobe® pump series is suitable for both manual cleaning and

CIP (Cleaning In Place), refer to section 3.3.2.

The product seals are mounted directly behind the rotors and are

designed and positioned to minimize product entrapment and maximize
the effects of cleaning.

This strategic positioning of the product seals, combined with their ease

of access provides an arrangement that can be more effectively
cleaned by both manual and CIP procedures.

It is recommended that the exterior of the pump is cleaned periodically.

2.5 Pump Model Designation.

The designation of pump models are as follows:

S1S S3S
S1M S3M
S1L S3L
S2S S4S
S2M S4M
S2L S4L

This information, together with the pump serial number, should be

provided when requesting additional information on the pump or when
ordering spare parts. The pump serial number is stamped on the pump
nameplate and the rotorcase, (refer to section 2.6, Figs 2 and 3).

For the maximum operating pressures, temperatures and speeds refer

to section 3.2, Fig 6.

Page : 8

2.5.1 Atex Information Plate

Category 2

Group II.

2.5.2 Equipment Groups & Catergories

Unit is suitable for

environments containing

dust or gas

Temperature Class.

Page : 9

2.6 Pump Model and Serial Number.

V

Should you require any information regarding your Duralobe® rotary

lobe pump contact Viking Pump or your Viking Pump distributor,
providing the pump model and serial number as stated on the pump
nameplate, see Fig 2, which is fixed to the pump gearbox cover.

Should this be damaged or missing, the pump serial number is also

stamped on opposite corners of the rotorcase, (see Fig 3).

Fig 2

IKING

PUMP

IDEX CORP ORATION

MODEL

FI LL TO SI GHT LEVEL
RECOMMENDED LUBRICANT

SERI AL NUMBER

BUILD CODE

MADE IN GREAT BRI TAIN

A Uni t of I DEX Cor po r a t i onVI KI NG PUMP I NC.

USACEDAR FALLS , I A

Fig 3

Page : 10

2.7 Standard Pump Component Terms.

Fig 4

Page : 11

3.0 General.

3.1 Duralobe® Pumping Principle.

The pumping action of the rotary lobe pump principle is generated by the
contra-rotation of two pumping elements (rotors) within a chamber (rotorcase),
see Fig 5. The rotors are located on shafts which in turn are held within two
cartridges mounted onto the back of the rotorcase. The shaft cartridge
assemblies comprise of, the shaft support bearings and the timing gears. The
gears transfer the energy from the drive shaft to the driven shaft,
synchronizing the rotors such that they rotate without contact with each other.
As the rotors pass the suction port, Fig 5a, the cavity increases creating a
pressure decrease, which induces the pumped medium to flow into the
rotorcase.

The pumped medium is carried around the rotorcase by the rotors, Fig 5b and
5c, to the discharge side of the pump, Fig 5d. Here the cavity decreases and
the pumped medium is discharged from the rotorcase, Fig 5e.

For pump component terms see Fig 4.

Fig 5 Rotary Lobe Pump Principle.

Page : 12

3.2 Duralobe® Pump Operating Parameters.

Fig 6

Pump

Series

Theoretical Displacement

Liter /

rev

Imp.gal

/100 rev

US gal

/100

rev

Nominal

Connection

Size

Max Diff.
Pressure

Maximum

Speed

Max

Temp

Max

Temp

mm inches bar psi rev/min °C °F

S1S 0.04 0.88 1.06 25 1 14 200 1150 150 300

S1M 0.06 1.32 1.59 25 1 10 150 1150 150 300

S1L 0.08 1.76 2.11 25 1 7 100 1150 150 300

S2S 0.17 3.74 4.49 38 1.5 14 200 1150 150 300

S2M 0.25 5.50 6.61 50 2 10 150 1150 150 300

S2L 0.34 7.48 8.98 50 2 7 100 1150 150 300

S3S 0.54 11.88 14.27 50 2 14 200 870 150 300

S3M 0.81 17.82 21.40 76 3 10 150 870 150 300

S3L 1.08 23.76 28.53 76 3 7 100 870 150 300

S4S 1.62 35.64 42.80 76 3 14 200 700 150 300

S4M 2.43 53.46 64.20 101 4 10 150 700 150 300

S4L 3.24 71.28 85.60 101 4 7 100 700 150 300

The maximum pressure and speed operating parameters are given in Fig 6.
In practice these may be limited due to the nature of the product to be
pumped and/or design of the system in which the pump is to be installed.
Consult Viking Pump or your Viking Pump distributor for assistance.

If the system or product characteristics are to be changed from the

WARNING

original application for which the pump was selected, Viking Pump or
their authorized distributor should be consulted to ensure the pump is
suitable for the new application.

The pump should not be subjected to sudden temperature changes to avoid
the risk of damage from sudden expansion/contraction of components. Care
should be taken when selecting pumps for handling liquids containing
abrasive particles as these may cause wear of pump head components. For
advice or assistance contact Viking Pump or your Viking Pump distributor.

Page : 13

3.3 System Design.

3.3.1 System Design and Installation.

i) Be sure ample room is provided around the pump to allow for:

a) Access to the pump and drive for routine inspection and

b) Ventilation of the drive to prevent over heating.

WARNING

ii) The pump must not be used to support piping. All piping to and from

iii) Valves should be provided adjacent to the pump suction and discharge

iv) Rotary lobe pumps are of the positive displacement type and therefore

a) A pressure relief valve integral with the pump where available and

b) An in-line pressure relief system, i.e. external to the pump.

c) Incorporation of a torque limiting device in the drive system.

d) Rupture disc incorporated in the discharge piping.

When incorporating any pump into a system it is considered good practice to
minimize piping runs and the number of pipe fittings (tees, unions, bends etc.)
and restrictions. Particular care should be taken in designing the suction line,
which should be as short and straight as possible with a minimum of pipe
fittings to minimize restricting product flow to the pump. The following should
be considered at the design stage of any system:

maintenance, i.e. to replenish pump or drive lubricant or to
remove pump front cover and rotors.

the pump unit must be independently supported. Failure to observe
this may distort the pump head components or assembly and cause
serious consequential damage to the pump.

connections to allow the pump to be isolated from the system for
routine inspection and maintenance.

an overload protection device must be provided. This can take the form
of:

suited to the application, refer to section 3.8.

Where pump rotation and hence flow is to be reversed during normal
operation, the overload device must be capable of protection for both
directions of rotation/flow. The Duralobe® integral relief valves are described
in section 3.8 and are designed to operate under such conditions.

Page : 14

WARNING

v) It is recommended that all piping and associated equipment from the

vi) Pressure gauges should be installed adjacent to the pump suction and

WARNING

vii) It is imperative that the suction condition at the pump inlet meets the

WARNING

WARNING

tank to the discharge point is thoroughly cleaned before installation of
the pump to avoid the possibility of debris entering the pump and
causing damage.

discharge connections such that system pressures can be monitored.
These gauges will provide a clear indication of changes in operating
conditions and where a relief valve is incorporated in the system, will
be necessary for setting and checking the functioning of the valve.

Net Positive Suction Head Required (NPSHr) by the pump. Failure to
observe this could cause cavitation, resulting in noisy operation,
reduction in flow rate and mechanical damage to the pump and
associated equipment.

The Net Positive Suction Head Available

(NPSHa) from the system must
always exceed the Net Positive Suction Head Required (NPSHr) by the pump.
Observing the following general guidelines should ensure the best possible
suction condition is created.

- Suction piping is at least the same diameter as the pump connections.

- The length of suction piping is kept to the absolute minimum.

- The minimum number of bends, tees and pipework restrictions are

used.

- That calculations to determine system NPSHa are carried out for the

worst condition, see Fig 7.

Should advice on pump or system NPSH characteristics be required contact
Viking Pump or your Viking Pump distributor.

Fig 7

Page : 15

(viii) When installing a pump complete with baseplate, motor and drive the

a) The preferred drive arrangement for any rotary lobe pump is in-line direct

b) Flexible couplings must always be incorporated and correctly aligned within

Couplings of a non flexible design must never be used.

c) Couplings must always be enclosed in a suitable guard to prevent contact with

d) When installing pump sets in flammable or explosive environments, or for

e) Baseplates must be secured to a flat level surface such that distortion and

f) When using electric motor drives, ensure that the electrical supply is

3.3.2 Installations with CIP Systems.

The Duralobe

3.4 Start Up Procedure.

WARNING

WARNING

following guidelines must be observed:

coupled. If an alternative is required please contact Viking Pump or your
Viking Pump distributor.

the limits recommended by the coupling manufacturer. To check coupling
alignment rotate the shaft by at least one full revolution and ensure that the
shaft rotates smoothly.

rotating parts which could result in personal injury. Guards should be of
suitable material ,(see d) and of sufficiently rigid design to prevent contact
with rotating parts under normal operating conditions.

handling flammable or explosive materials, special consideration must be
given not only to the safety aspects of the drive unit enclosure but also to the
materials used for both the coupling and the guard to eliminate the risk of
explosion.

misalignment are avoided. Once baseplates are fastened in position the

drive alignment must be re-checked, (see b).

compatible with the drive and controls and that the method of wiring is
correct for the type of starting required by the motor i.e. Direct On Line, or
other similar method. Ensure all components are correctly grounded.

®

has been designed to be effectively cleaned by the CIP
procedures recommended for in place cleaning of process equipment. It is
recommended that a differential pressure of 30 to 45 psi be developed across
the pump head during cleaning in order to develop the necessary fluid
velocities required for thorough cleaning.

- Check that all piping and associated equipment are clean and free from

debris and that all pipe connections are secure and leak free.

- For pumps installed with flushed product seals check that all auxiliary

services are in place and connected and provide sufficient flow and
pressure for flushing purposes, refer to section 4.3.7.

Page : 16

WARNING

WARNING

WARNING

WARNING

Fig 8

- Ensure lubrication is provided for both pump and drive. Duralobe®

pumps are shipped without oil and should be filled to the level of the oil
sight glass which must be installed in the upper tapped hole in the side
of the gearbox cover, refer to section 5.3 for pump oil capacities and
grades.

- If an external relief valve is incorporated in the system check that it is

set correctly. For start up purposes it is considered good practice to set
the relief valve lower than the system design pressure. On completion
of start up the relief valve should be reset to the required setting for the
application. The required setting should never exceed the lower of
either the pumps maximum pressure rating or the system design
pressure. For setting integral relief valves, refer to sections 3.8.1 and

3.8.2.

- Ensure both suction and discharge valves are fully open, and pipework

is free from all obstructions. Duralobe® pumps are of the positive
displacement type and should therefore never be operated against a
closed valve as this would result in pressure overload, resulting in
damage to the pump and possibly the system.

- Ensure rotation of the drive shaft is correct for the direction of flow

required, see Fig 8.

WARNING

-Before beginning operation it is considered good practice to

-Ensure product is available in the tank before starting pump. This is
very important for pumps installed with unflushed product seals as
these sealing arrangements must never be allowed to run dry.

momentarily start/stop the pump to check the direction of rotation and
ensure that the pump is free of obstructions. Once this has been
carried out, begin operation keeping a visual check on suction and
discharge pressure gauges and monitor pump temperature and power
absorbed where possible.

Page : 17

3.5 Shutdown Procedure.

When shutting the pump down close both the suction and discharge valves

- The prime mover power source has been isolated.

- If installed, the pneumatically operated integral relief valve has been

- If Installed, flushed product seal auxiliary services have been isolated

- Pump head and piping have been drained and purged.

3.6 Routine Maintenance.

WARNING

- Check oil levels regularly.

- For lubricant capacities and grades refer to section 5.3.

3.7 Heating and Cooling Devices
see Figs 9 and 10.

and ensure that the necessary safety precautions are taken:

depressurized.

and depressurized.

- Change the oil every 12 months or 3000 operating hours whichever is

the sooner.

All Duralobe® models except the S1 series, can be supplied with a jacketed
front cover and rotorcase with ports for circulation of a heating/cooling media.
The jacketed front cover and rotorcase heating and cooling ports are
strategically positioned such that the required thermal effect acts on the
pumping chamber and product seal area.

The pressure rating of the Duralobe® series jacketed front cover and
rotorcase heating/cooling ports is 50 psi and should not be exceeded without
consulting Viking Pump or your local Viking Pump distributor.

Heating/cooling of the pump head is used to maintain, rather than
increase/decrease the temperature of the pumped media and should be used
as part of a complete system where suction and discharge lines and vessels
are also heated/cooled.

Where heating/cooling devices are employed, the heating/cooling media
should be circulated 15-20 minutes prior to pump start-up and should be
allowed to continue for a similar period of time after the pump has been
shutdown. Where a CIP cycle is employed as part of the process, the

heating/cooling media should continue to be circulated during the cleaning
cycle.

Page : 18

Fig 9 Dimensions of Front Cover Jacket for Heating/Cooling.

Model

S1S

S1M

S1L
S2S

S2M

S2L
S3S

S3M

S3L
S4S

S4M

S4L

Note: For all other dimensions see section 5.5, Foundation Dimensions and

Weights.

Millimeters Inches

A6 M1 A6 M1 Y4

45.0

45.0

45.0

70.0

70.0

70.0

105.0

105.0

105.0

150.0

150.0

150.0

52.0

54.0

54.5

70.0

75.0

76.0

95.0

104.0

104.0

113.0

126.0

133.0

1.77

1.77

1.77

2.76

2.76

2.76

4.13

4.13

4.13

5.91

5.91

5.91

2.05

2.13

2.15

2.76

2.95

2.99

3.74

4.09

4.09

4.45

4.96

5.24

¼
¼
¼
½
½
½
½
½
½
½
½
½

Page : 19

Fig 10 Dimensions for Rotorcase Ports for Heating/Cooling.

Model

S1S

S1M

S1L
S2S

S2M

S2L
S3S

S3M

S3L
S4S

S4M

S4L

Note: For all other dimensions see section 5.5, Foundation Dimensions and

Weights.

A7 BF M2 A7 BF M2 Y5

N/A
N/A
N/A

80.0

80.0

80.0

102.5

102.5

102.5

140.0

140.0

140.0

Millimeters Inches

N/A
N/A
N/A

66.5

66.5

66.5

90.5

90.5

90.5

137.0

137.0

137.0

N/A
N/A
N/A

14.0

24.5

36.0

16.0

25.0

49.0

22.0

35.0

64.0

N/A
N/A
N/A

3.15

3.15

3.15

4.04

4.04

4.04

5.51

5.51

5.51

N/A
N/A
N/A

2.62

2.62

2.62

3.56

3.56

3.56

5.39

5.39

5.39

N/A
N/A
N/A

0.55

0.96

1.42

0.63

0.98

1.93

0.87

1.38

2.52

N/A
N/A
N/A

1/8
1/8
1/8
1/8
1/8
1/8
1/8
1/8
1/8

Page : 20

3.8 Integral Pressure Relief Valves
see Figs 11, 12, 13 and 14.

All models in the Duralobe® series can be supplied with integral pressure

relief valves with both spring and air loaded versions available. The function of
the valves can be further enhanced with the option of manual or airlift override
offering particular benefits where CIP or SIP is employed. Valves
incorporating this option can be opened to regulate the volume of the cleaning
media within the pump chamber thereby avoiding the need for manual
cleaning or external by-pass.

Where the pump is mounted onto a portable cart baseplate complete with
motor and drive to be used as a mobile set, it is strongly recommended that a
integral pressure relief valve is installed.

The Duralobe® integral pressure relief valves available include:

Spring Loaded - see Fig 11.

Valve can be set to required pressure relief setting.

Spring Loaded with Manual Lift - see Fig 12.

Valve can be set to required pressure relief setting. Manual lift override can
be used to open valve without disturbing pressure relief setting (not
available on the S4 series).

Spring Loaded with Air Lift - see Fig 13.

Valve can be set to required pressure relief setting. Air lift override, which
operates on an air supply of up to 105 psi depending on pressure relief
setting, can be used to open valve without disturbing pressure relief setting
(not available on the S4 series).

Air Loaded with Air Lift - see Fig 14.

Valve, which operates on an air supply of up to 105 psi for S1, S2, S3 and
150 psi for S4, can be set to required pressure relief setting. Air lift override,
which operates on an air supply of up to 105 psi for S1,S2,S3 and 150 psi
for S4, depending on pressure relief setting, can be used to open valve
without disturbing pressure relief setting.

Air actuated relief valves can be operated remotely and interfaced with other
elements of the system or process control.

Integral pressure relief valves are normally used to protect the pump from the
effects of increases in system pressure caused, for example, by a restricted or
closed discharge line. In response to a pressure increase the valve opens
and internally circulates the pumped media within the pump chamber.

Page : 21

WARNING

3.8.1 Setting and Operating Spring Loaded Valves
see Figs 11, 12 and 13.

WARNING

- Reinstall cover (108). For integral relief valve with manual lift, see Fig 12,

WWHHEENN TTHHEE VVAALLVVEE OOPPEENNSS,, BBEECCAAUUSSEE TTHHEE VVOOLLUUMMEE OOFF FFLLUUIIDD
CCIIRRCCUULLAATTIINNGG IISS RREELLAATTIIVVEELLYY SSMMAALLLL,, TTHHEE TTEEMMPPEERRAATTUURREE OOFF TTHHEE
FFLLUUIIDD IINN TTHHEE PPUUMMPP CCHHAAMMBBEERR MMAAYY RRIISSEE IIFF TTHHEE PPUUMMPP CCOONNTTIINNUUEESS TTOO
OOPPEERRAATTEE FFOORR AANN EEXXTTEENNDDEEDD PPEERRIIOODD.. IINN SSEEVVEERREE CCAASSEESS TTHHIISS MMAAYY
RREESSUULLTT IINN TTEEMMPPEERRAATTUURREESS IINN EEXXCCEESSSS OOFF TTHHEE PPUUMMPPSS OOPPEERRAATTIINNGG
LLIIMMIITTSS OORR VVAAPPOORRIIZZAATTIIOONN OOFF TTHHEE FFLLUUIIDD,, BBOOTTHH OOFF WWHHIICCHH SSHHOOUULLDD BBEE
AAVVOOIIDDEEDD.. FFOORR TTHHEESSEE RREEAASSOONNSS WWHHEENN TTHHEE VVAALLVVEE IISS AACCTTIIVVAATTEEDD
TTHHEE CCAAUUSSEE OOFF TTHHEE SSYYSSTTEEMM PPRREESSSSUURREE IINNCCRREEAASSEE SSHHOOUULLDD BBEE
EELLIIMMIINNAATTEEDD AASS CCOONNTTIINNUUOOUUSS OOPPEERRAATTIIOONN OOFF TTHHEE PPUUMMPP WWIITTHH TTHHEE
VVAALLVVEE OOPPEENN IISS NNOOTT RREECCOOMMMMEENNDDEEDD AANNDD MMAAYY CCAAUUSSEE SSEEVVEERREE
DDAAMMAAGGEE TTOO TTHHEE PPUUMMPP..

If the pump on which the valve is installed is to be installed in either a
pressurized system or one incorporating a vessel under vacuum, the
application of the valve should be referred to Viking Pump or their authorized
distributor.

The selection, setting and application of integral relief valves is influenced by
the viscosity and nature of the pumped media, the pump operating speed and
the required pressure relief setting and mode of operation. For these reasons,
and to cover the diverse range of products, the conditions under which they
are pumped, and application demands, it is not practical to factory set integral
relief valves. The setting of the valve should be carried out on site under the
proposed duty conditions for which the pump and valve were selected.

For setting and operating Duralobe® integral relief valves refer to sections

3.8.1 and 3.8.2. Before beginning the relief valve setting procedure the pump
should be installed, refer to section 3.3.1, with a pressure gauge in the
discharge line adjacent to the pump discharge port.

- Remove cover (108). For integral relief valve with manual lift, see Fig

12, first remove nut (129) and handwheel (111).

- Loosen nut (107) using a pry bar in the holes provided, to relieve spring

compression. For integral relief valve with air lift, see Fig 13, the air
cylinder must be exhausted prior to unscrewing the nut (107).

- Start pump, refer to section 3.4.

- Screw in nut (107) using pry bar in holes provided until required

pressure relief setting is reached.

Note: Care should be taken not to exceed the lower of either the pumps
maximum pressure rating or the system design pressure.

reinstall handwheel (111) and nut (129).

Page : 22

- The relief valve is now set.

For Integral Relief Valve with Manual Lift - see Fig 12.

- To operate the manual lift, turn the handwheel (111) clockwise which will

For Integral Relief Valve with Air Lift - see Fig 13.

To actuate the air lift connect an air supply not exceeding 105 psi for S1,

3.8.2 Setting and Operating Air Loaded Valve
see Fig 14.

- Connect an air supply, via a regulating valve to the relief valve

- Start the pump, refer to section 3.4.

- Using the regulating valve gradually increase the air pressure until

- The relief valve is now set.

WARNING

- To use the air lift system the regulated air supply must be routed through

lift the valve head (102/128). To resume normal operation turn the
handwheel (111) counter-clockwise.

S2, S3 and 150 psi for S4 to the cylinder (123) which will lift the valve
head (112). To resume normal relief valve operation exhaust the cylinder
(123).

connection A in the cylinder (114). Do not turn on the air supply.

required pressure relief setting is reached. The air pressure must not
exceed 105 psi S1, S2, S3 and 150 psi S4.

- S4 Only - If the valve assembly is disassembled, e.g. for maintenance

or repair, it is necessary to apply a thread locking compound (Loctite
270 or similar) to the piston retaining screw (120).

Note: Care should be taken not to exceed the lower of either the pumps

maximum pressure rating or the system design pressure.

a change over valve in order to transfer air from the relief valve load air
chamber, connection A, to the lift air chamber, connection B while
depressurizing the load chamber and vice versa. The change over valve
will actuate the air lift which will lift when the air supply is diverted to
connection B, and will close, restoring normal relief valve operation, when
the air supply is diverted back to connection A.

Page : 23

Danger

Under no circumstances should any attempt be made to dismantle a pressure
relief valve which has not had the spring pressure relieved, is still connected
to a pressurised air supply, or is mounted on a pump that is operating.
Serious personal injury or pump damage may occur.

Fig 11 Spring Loaded Integral Pressure Relief Valve S1, S2, S3 Typical.

Page : 24

Fig 12 Spring Loaded Integral Pressure Relief Valve with Manual Lift
S1, S2, S3 Typical.

Page : 25

Fig 12.5 Spring Loaded Integral Pressure Relief Valve S4 Typical.

103B

103A

128

102

110A

131

112

109

110A

110B

127

106

126

108

107

107

Page : 26

Fig 13 Spring Loaded Integral Pressure Relief Valve with airlift

S1, S2, S3 Typical.

Page : 27

Fig 14 Air Loaded Integral Pressure Relief Valve with airlift
S1, S2, S3 Typical.

Page : 28

Fig 14.5 Air Loaded Integral Pressure Relief Valve with airlift S4 Typical

B

A

Page : 29

4.0 Duralobe® Pump Dismantling and Assembly.

WARNING

Before undertaking any work on the pump the recommended Shutdown
Procedure should be followed, refer to section 3.5, and site safety practices
must be observed.

While dismantling or assembling the pump it is essential to ensure that the
pump and/or components are secured to provide adequate stability.

Large pump components or sub assemblies should be lifted using suitable
devices. Use threaded holes for the attachment of lifting eyes where
appropriate.

During dismantling or before assembly all components should be inspected
for fit, wear and damage. If worn or damaged the components should be
replaced before re-assembly.

The position of all parts should be identified as they are removed to ensure
they are reinstalled in the same position.

Lipseals and o-rings are incorporated within the shaft cartridge assemblies
and the gearbox cover to contain the lubricant for the bearings and timing
gears. Regular inspection and correct maintenance of these items will ensure
that the lubrication is sustained and the pump maximum working life is
achieved. To ensure this, it is extremely important that care is taken when
removing and installing new o-rings and lipseals. When removing and
replacing lipseals ensure that the location bore for the outside diameter and
the seat for the back of the lipseal is not damaged as this may create a leak
path for the lubricant.

When removing lipseals or o-rings care should be taken to avoid cutting
or tearing the sealing faces as they pass over keyways, splines, threads
or other potentially sharp or abrasive edges. All lipseals and o-rings should

be carefully examined and if damaged in any way, replaced on assembly.

All o-rings and sealing lips of lipseals should be lightly lubricated with a
suitable lubricant (silicon grease, etc.) before installing.

When installing lipseals do not allow the rear face to come into contact with
bearings.

Prior to beginning assembly, ensure all parts are clean and free from burrs or
damage. Where a vice is to be used, it should have protective jaws to avoid
damage to components. Do not hammer or apply undue force to install or
position components.

All fasteners are required to be tightened to the required torque setting during
assembly, refer to section 5.2.

Page : 30

The preferred method of installing bearing cones is to heat them to
approximately 250°F prior to installation. During this operation protective
gloves should be used. Once bearing cones are installed in correct position
they should be allowed to cool before proceeding with assembly. As an
alternative, bearing cones may be pressed into position providing the proper
equipment is employed and the necessary procedures are used to prevent
component damage.

Under no circumstances should bearing cones or cups be hammered
into position.

For torque settings of fasteners and shaft rolling torque, see section 5.2.

4.1 Disassembly.

4.1.1 Front Cover and Rotor Removal - see Fig 15.

- Follow recommended Shutdown Procedure, refer to section 3.5.

- Gradually loosen front cover retaining dome nuts (36). Care should be

taken as there may still be residual product and pressure in the pump
head. As the dome nuts are loosened this will vent to atmosphere.

- Remove dome nuts (36) .

- Remove front cover (38), using lever slots where necessary, and the

front cover o-ring (39).

- Remove rotor retainers (35) using socket (58).

WARNING

Note: The socket (58) should always be used. The use of other
tools may damage the retainer.

- Remove retainer o-ring (34).

- Remove rotors (41) from shafts (items 9 and 10 see fig 5.6 on page

60), taking care not to damage the product seal components.

Page : 31

Fig 15 Front Cover and Rotor Removal.

Page : 32

4.1.2 Cartridge Removal
(after completing 4.1.1) - see Fig 16.

The following procedures assume the pump has been removed from the
baseplate.

Remove product seals before proceeding with cartridge removal, refer to
section 4.3.

- Remove oil drain plug (5) and breather (21). Drain oil into suitable
container and retain if later inspection is required.

- Remove drive coupling (not shown).

- Remove drive key (8).

- Remove gearbox cover retaining screws (7).

- Remove gearbox cover (16) and gasket (3).

- Remove lipseal (11) from gearbox cover (16).

- Remove shaft cartridge retaining screws (23).

- Extract shaft cartridge assembly using lever slots if necessary, taking

care not to damage the shims (22 – not shown). The shaft cartridge is
an assembly of parts 20, 19, 25, 24, 17, 57, 8, 14, 13, 12, 22, 8, and 9
or 10 (items 9 and 10 see fig 5.6 on page 61). Keep shims (22) in sets
and identify position.

Note: Shims (22) may be different for each cartridge and therefore

should be kept with their respective cartridge.

Fig 16

3

16

Page : 33

4.1.3 Cartridge Disassembly
see Fig 17.

- Remove locknut (12) and tab washer (13).

- Remove timing gear (14) noting that the drive shaft gear (stamped D)

has a right hand helix and the driven shaft gear (stamped L) a left hand
helix.

- Remove gear key (57).

- Remove front oil seal (17).

- Remove shaft (9 or 10) from bearing sleeve (20).

- Remove bearing inner cones (24) from shafts (9 and 10).

- Remove bearing cups (24) from bearing sleeves (20).

Fig 17

Page : 34

4.2 Assembly.

4.2.1 Cartridge Assembly
See Figs 18, 19, 20, 21 and 22.

- Install bearing cups (19) and (24) to bearing sleeves (20).

Fig 18

Page : 35

Fig 19

Fig 20

- Heat cones to 250°F and install front bearing cones (24) onto shafts

(items 9 and 10 see fig 5.6 on page 60).

- Install bearing sleeves (20) to shafts (items 9 and 10 see fig 5.6 on

page 60) with securing lugs towards the spline end of the shaft so that
the bearing cup locates with the cone (24).

Page : 36

Fig 21

- Heat cones to 250°F and install rear bearing cones (19) to shafts

(items 9 and 10 see fig 5.6 on page 60). Do not use excessive
pressure as rolling torque is achieved by adjusting rear lock nuts (12).

- Install gear keys (57) and gears (14) into position insuring that the gear

boss contacts with the rear bearing cone (19).

Note: Right hand helix for drive shaft gear (stamped D), left hand helix

for driven shaft gear (stamped L).

Note: When ordering spare timing gears it is essential to purchase and

install these as a pair.

Page : 37

Fig 22

- Install tab washers (13) and lock nuts (12). Do not secure tab washers

(13).

- Tighten lock nuts (12) and adjust to achieve correct rolling torque, refer

to section 5.2. To measure the rolling torque, place assembled
cartridge, with the splined end of the shaft uppermost, into a vice
gripping on the bearing sleeve. Do not over tighten the vice as the
sleeve is a precision component and should not be distorted.
Screw a bolt into the tapped hole in the splined end of the shaft. Rotate
the shaft by means of the bolt using a torque meter. If the rolling torque
does not correspond to the required setting, adjust lock nuts (12).

- Secure tab washer (13) after setting correct rolling torque.

- Install lipseals (17) to bearing sleeves (20).

Page : 38

4.2.2 Cartridge to Rotorcase Assembly

see Fig 23.

- If not already installed, mount feet (1) to rotorcase (item 40 see fig 5.6)

in the required positions using caphead screws (2). Install the relevant
product seal housing (28, 44, 47 or 156) with associated gasket or o­ring or lipseal (single flushed and double flushed mechanical seals
only) and wave spring (single mechanical seal only) to the rear of the
rotorcase (40) and secure with screws (26).

- Install o-rings (25) to front diameter of bearing sleeves (20).

- Assemble cartridges into rotorcase (40) rear bores insuring that timing

marks on the timing gears (14) are in mesh (single dot on drive shaft
gear, two dots on driven shaft gear). The timing gears are in correct
mesh when the single dot on the drive shaft gear is between the two
dots on the driven shaft gear. Leave a small gap between rear face of
rotorcase (40) and cartridge mounting face for inserting shims (22).

- Insert shims (22) between rotorcase (40) and cartridge. Shims can be

plastic or steel and are either marked with their thickness or are color
coded as follows :

Blue = 0.050mm thick (0.002”)
Green = 0.075mm thick (0.003”)

Clear = 0.150mm thick (0.006”)
White = 0.250mm thick (0.010”)

- Secure cartridges to rotorcase (40) with cap head screws (23),

tightening to correct torque, refer to section 5.2.

- Install rotors (41), refer to section 4.2.3.

- Using a depth micrometer or similar device measure "actual" rotor front

clearance. This is the clearance between the front face of the rotorcase
and the front face of the rotor. Select "required" front clearance (A)
from the Clearance Chart, refer to section 5.1. The difference between
the "actual" measured clearance and the "required" clearance, as given
on the Clearance Chart, is the amount of shim (22) that needs to be
removed or added.

- Having determined the amount of shim (22) to be removed or added,

remove rotors (41), refer to section 4.1.1. Remove cap head screws
(23). Taking care not to damage the shims (22), ease cartridge from
rotorcase (40) using lever slots to create a gap to access the shims
(22). Remove or add appropriate amount of shim between rotorcase
(40) and shaft cartridge flange.

- Secure cartridges to rotorcase (40) with cap head screws (23)

tightening to correct torque, refer to section 5.2.

Page : 39

Fig 23

Page : 40

4.2.3 Rotor Assembly and Setting Rotor Clearances

see Fig 24.

Note: The retainer o-ring (34) seals the shaft/rotor spline and should not

Note: When fitting mechanical seals be sure that the seal stationary

WARNING

WARNING

- Do not install product seals at this point.

- Install rotors (41) onto shafts (9 and 10) in rotorcase (40), install

retainer o-ring (34) into bore in rotor and secure with rotor retainer (35)
set to the correct torque (see section 5.2) using socket (58).

be re-used if cut, distorted or damaged in such a way as to impair its
ability to form a seal. If in doubt a new o-ring should always be installed.

- Using a depth micrometer or similar device measure front clearance

(A) between the rotorcase and rotor front faces and check that this
corresponds to the appropriate clearance as indicated on the
Clearance Chart, refer to section 5.1.

- If the front clearance (A) is incorrect adjustment of the shims (22)

between the rotorcase and cartridge is required, refer to section 4.2.2
Cartridge to Rotorcase Assembly.

- With rotors (41) installed, check all clearances, front (A), radial (C), rear

(B) and mesh (D), against the Clearance Chart, refer to section 5.1.
Remove rotors (41) and install product seals, refer to section 4.3
Product Seal Fitting and Removal, and reassemble rotors (41)
tightening to the correct torque.

seat (31) is properly engaged with the seal housing (28) drive pin or
serious damage to the pump will result.

- Install o-ring (38) to front cover (39).

- Install front cover (39) to rotorcase (40), securing with dome nuts (36),

tightening to correct torque, refer to section 5.2.

Note: It is recommended that rotors should be installed in pairs,
although parts are available individually.

Page : 41

Fig 24

Page : 42

4.2.4 Gearbox Cover Assembly

see Fig 25.

Note: The sight glass (6) must be Installed in the upper tapped hole in

WARNING

Fig 25

- Install lipseal (11) to gearbox cover (16).

- Install breather (21), drain plug (5) and sight glass (6) in required

position in gearbox cover (16).

the side of the gearbox cover (16). Remember to fill the gearbox with oil
prior to start up. For recommended lubricant capacities and grades
refer to section 5.3.

- Install gearbox cover (16) with gasket (3) to rotorcase (40) securing

with screws (7), tightening to the correct torque, refer to section 5.2.

Page : 43

4.3 Product Seal Fitting and Removal.

4.3.1 General Procedures for Fitting Mechanical Seals.

WARNING

"Quick summary" of mechanical seal installation.

- Mechanical seals are precision engineered assemblies incorporating

finely lapped seal faces and seats. They must therefore be handled
with care and will not give optimum performance unless installed
carefully and according to instructions.

- Where mechanical seals are to be reused insure that seal components

are kept in their appropriate sets. Do not mix old and new seal faces

on the same seal.

- Remove any sharp corners and burrs that may damage any elastomers

such as o-rings or lip seals.

- Insure that all seal component fitting bores and housings are

thoroughly cleaned before installation.

- The seal faces and seats must be handled with care and cleaned

thoroughly before installation.

- Insure that seal faces are undamaged and the o-rings are not cut,

swollen or cracked.

- All o-rings should be lightly lubricated with a suitable lubricant (silicon

grease, soap etc.) before fitting but insure there is no excessive
amount of lubricant especially around the seal face area.

- When fitting PTFE encapsulated o-rings it is important to immerse

them in hot water for several minutes to soften them.

- Insure seal seats are mounted squarely in the rotorcase.

- Insure when installing seals with brittle faces such as silicon carbide

that extra care is taken.

- Do not use any excessive force to install a mechanical seal. If it is

difficult to position and assemble the seal then something is wrong.

- If you drop or damage a seal, do not install it before an inspection has

been carried out.

- Do not run a mechanical seal dry.

Page : 44

4.3.2 Single Mechanical Seal
See Fig 26.

Fig 26

Read the General Procedures to prepare for seal installation refer to section 4.3.1
before assembly Ensure that all seal components are clean and grease free.

- Install wave springs (29) to housings (28).

- During Pump assembly install housings (28) to rotorcase securing with

screws (26) tightening to correct torque, refer to section 5.2. If only the
seal faces are being replaced, the housings (28) and wave springs (29)
will already be in place.

- Install o-rings (32) to rotors (item 41 see fig 5.6 on page 60).

- Install rotary seal faces (33) into rotors (item 41 see fig 5.6) ensuring that

the drive lugs and drive slots engage. Make sure the o-rings (32) are
located correctly and that the seal faces (33) are sitting squarely in the
rotors (item 41 see fig 5.6).

- Install o-ring (30) to stationary seat (31).

- Gently push the stationary seat and o-ring (30,31) assemblies into the

seal housings (28), ensuring drive pins and slots are engaged.

- You should now be able to feel the resistance being generated by the

wave spring (29).

Page : 45

Removal of Single Mechanical Seals.

WARNING

WARNING

Fig 27 Use of Seal Face Extraction Tool.

- Ensure pump is fully shutdown, refer to section 3.5.

- To remove single mechanical seals, reverse the above procedure using

the extraction tool (61) to aid in the removal of the seal faces, see fig

27.

Note: If seals are being reused, ensure that seal faces remain matched.

- With reference to fig 26 remove rotary seal faces (33) from rotors (41)

using the extraction tool (61). This is achieved by inserting the
extraction tool between the rotary seal face (33) and the rotor (41)
applying a twisting action, see fig 27. It may be necessary to alternate
from side to side in order to facilitate removal.

- The static seal face (31) can be removed by using the same technique.

Note: Extreme care should be taken when carrying out these procedures
to ensure that the seal faces are not damaged. No excessive force is
necessary if the extraction tool is used correctly.

Page : 46

4.3.3 Single Flushed Mechanical Seal
(for low-pressure flush/quench) - see Fig 28.

Fig 28

Read the General Procedures to prepare for seal installation, refer to section

4.3.1.

- Install lipseal (43) to flushed housing (44).

- During Pump assembly Install housing (44) to rotorcase securing with

screws (26) tightening to correct torque, refer to section 5.2. Ensure the
gasket or o-ring (27) is in place before tightening screws (26).

- Locate thrust ring (42) into rotorcase (item 40 see fig 5.6) to engage with

flushed housing (44). Ensure wave spring (29) is installed to thrust ring
(42). If only the seal faces are being replaced the housing (44) and thrust
ring (42) will already be in place.

- Install o-rings (32) into rotors (item 41 see fig 5.6).

- Install rotary seal faces (33) into rotors (item 41 see fig 5.6) ensuring that

the drive lugs and drive slots engage. Make sure the o-rings (32) are
located correctly and that the seal faces (33) are sitting squarely in the
rotors (item 41 see fig 5.6).

- Install o-rings (30) to stationary seats (31).

Page : 47

Disassembly of Single Flushed Mechanical Seals.

WARNING

- Gently push the stationary seat and o-ring assemblies (30 and 31) into the

thrust rings (42), ensuring drive pins and slots are engaged.

- You should now be able to feel the resistance being generated by the

wave springs (29).

- Before final assembly, check that the seal faces are absolutely clean, use

a soft tissue and a suitable solvent based cleaner for best results.

Ensure pump is fully shutdown, refer to section 3.5.

To disassemble, reverse the above procedure using the extraction tool
supplied to aid in the removal of the seal faces, see fig 27.

- Remove rotary seal faces (33) from the rotors (41 see fig 5.6) using the

extraction tool (61). This is achieved by inserting the extraction tool
between the rotary seal face (33) and the rotor (41) and applying a
twisting action, see fig 27. It may be necessary to alternate from side to
side to facilitate removal.

- The static seal face (31) can be removed by using the same technique.

Note: Extreme care should be taken when carrying out these procedures
to ensure that the seal faces are not damaged. No excessive force is
necessary if the extraction tool is used correctly.

Page : 48

4.3.4 Double Mechanical Seal
(for high pressure flush) see Fig 29.

Fig 29

Read the General Procedures to prepare for seal installation, refer to section 4.3.1.
Before assembly Ensure that all seal components are clean and grease free.

- During Pump assembly Install housings (47) to rotorcase securing with screws
(26) tightening to correct torque, refer to section 5.2. Ensure the gaskets or o­rings (27) are in place before tightening screws (26).

- Install o-rings (45) to seal faces (46) and then install to shafts (items 9 and 10
see fig 5.6) ensuring engagement of pins with slots in shafts (items 9 and 10
see fig 5.6).

- Install o-rings (49 and 50) to seal cartridges (48 and 51).

- Install seal cartridge assemblies (comprising parts 29, 48, 49, 50 and 51) on

shafts (9 and 10 see fig 5.6) and push in until outboard seal faces (46) and
(48) come together. Take care not to damage the o-rings (49) and (50).

- You should now be able to feel the resistance being generated by the wave
springs (29).

- Install o-rings (32) into the rotors (item 41 see fig 5.6). Install rotary faces (33)
into rotors (item 41 see fig 5.6) ensuring that the drive lugs and the drive slots
engage. Make sure the o-rings (32) are located correctly and that the seal
faces (33) are sitting squarely in the rotors

Page : 49

WARNING

Fig 30 Use of Extraction Tool for the removal of Seal Faces.

Disassembly of Double Mechanical Seals.

Ensure pump is fully shutdown, refer to section 3.5.

To disassemble, reverse the above procedure using the extraction tool
supplied to aid in the removal of the seal faces, see Figs 27 and 30.

Note: If seals are being reused, Ensure that seal faces remain matched.

- Remove rotary seal faces (33) from rotors (41) using extraction tool (61).

This is achieved by inserting the extraction tool between the rotary seal
face (33) and the rotor (41) and applying a twisting action, see Fig 27. It
may be necessary to alternate from side to side to facilitate removal.

- Remove stationary seal cartridge assemblies (29,48 and 51) from the

shafts (9 and 10) by pulling off.

- Remove rotary seal face (46). This can be achieved by inserting the

extraction tool (61) through the drain/leakage detection holes in the sides
of rotorcase (40) and applying a twisting action, see fig 30. Note that this
procedure can not be applied to certain models of pumps installed with
flanged port connections. In this case, access to the rotary seal faces (46)
can be gained via the drilled holes in the top and bottom faces of the
rotorcase (40).

Note: Extreme care should be taken when carrying out these procedures

to Ensure that the seal faces are not damaged. No excessive force is
necessary if the extraction tool is used correctly.

Insert seal extraction tool into the drain/leakage detection slots at the side of the
rotorcase and apply a twisting action to remove the seal face (item 46 see fig 29
page 47).

Page : 50

4.3.5 Single O-ring Seal
Refer to Fig 31.

Fig 31

- During Pump assembly Install seal housings (156) to rotorcase securing
with screws (157).

- Install o-rings (155) inside bores of seal sleeve (153) using front groove.

Note: Do not lubricate o-rings (155).

- Install o-rings (154) on outside of seal sleeve (153) using front groove.

- Install seal sleeve assemblies (153,154,155) into rotorcase (item 40 see fig

5.6 on page 60) ensuring drive lugs locate with seal housings (156)
correctly.

- Install o-rings (151) into backs of rotors (41 see fig 5.6).

- Install seal sleeve (152) into rotors ensuring drive lugs locate with slots in

rotors.

- Install rotor assemblies to shafts refer to section 4.2.3. Care must be taken
when entering seal sleeve (152) into o-rings (155).

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

Page : 51

4.3.6 Double O-ring Seal
Refer to Fig 32.

Fig 32

- During Pump assembly Install seal housings (156) to rotorcase securing
with screws (157).

- Install o-rings (159) into grooves within the inside bore of seal sleeve (158).

Note: Do not lubricate o-rings (159).

- Install o-rings (154) into grooves on the outside of seal sleeve (158).

- Install seal sleeve assemblies (158,159,154) into rotorcase (item 40 see fig

5.6 on page 60) ensure drive lugs locate with seal housings (156) correctly.

- Install o-rings (151) into the back of rotors (item 41 see fig 5.6 on page 60).

- Install seal sleeve (152) into rotors (item 41 see fig 5.6 on page 60)

ensuring drive lugs locate with rotor slots correctly.

- Install rotor assemblies to shafts (items 9 and 10 see fig 5.6 on page 60),
refer to section 4.2.3. Care must be taken when entering seal sleeve (152)
into o-rings (159).

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

Page : 52

4.3.7 Trapped Sleeve
Fig 34

- Install the o-ring (66B) onto the shaft

- Install the trapped sleeve (66) onto the shaft

- Install the o-ring (66A) onto the shaft

Page : 53

4.3.8 Hybrid Double Mechanical 2000 Seal
Fig 35

- During Pump assembly fit the anti rotation washers (28B) to the rotorcase

securing with screws (26) tightening to correct torque, refer to section 5.2.

- Install the outboard o-ring (45) into the seal face (46).

- Before final assembly check that the seal faces are absolutely clean, use a

soft tissue and a suitable solvent based cleaner for best results.

- Install seal cartridge assembly (comprising parts 45, 46, 47, 76) onto the

shaft ensuring that the drive lugs and the drive slots engage.

- Install o-ring (49) into the seal seat (48).

- Install seal cartridge assembly (comprising parts 49, 48) into rotorcase,

ensure anti-rotation lugs and the anti-rotation washers (28B) engage.

- Install o-ring (50) to the static seal seat (31).

- Install the seal seat assembly (comprising parts 30, 31) into the rotorcase,

ensuring that the drive lugs and the drive slots engage.

- Install o-ring (32) onto the rotary seal face (33).

- Install the seal assembly (comprising parts 32, 33) onto the rotor.

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

Page : 54

4.3.9 Hybrid Double Mechanical Seal

Fig 36

- During Pump assembly fit the seal housing (28) to the rotorcase securing

with screws (26) tightening to correct torque, refer to section 5.2. Ensure
the gasket or o-ring (27) are in place before tightening screws (26)

- Install the outboard o-ring (45) into the seal face (46).

- Before final assembly check that the seal faces are absolutely clean, use a

soft tissue and a suitable solvent based cleaner for best results.

- Install seal cartridge assembly (comprising parts 45, 46, 47, 76) onto the

shaft ensuring that the drive lugs and the drive slots engage.

- Install o-ring (49) onto the seal seat (48).

- Install seal cartridge assembly (comprising parts 49, 48) into rotorcase,

ensure anti-rotation lugs and the anti-rotation washers (28B) engage.

- Install o-ring (50) onto the static seal seat (31).

- Install the seal seat assembly (comprising parts 30, 31) into the rotorcase,

ensuring that the drive lugs and the drive slots engage.

- Install o-ring (32) onto the rotary seal face (33).

- Install the seal assembly (comprising parts 32, 33) into the rotor.

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

Page : 55

4.3.10 Hybrid Single Flushed Mechanical Seal
Fig 37

- During Pump assembly fit the seal housing (28) to the rotorcase securing

with screws (26) tightening to correct torque, refer to section 5.2. Ensure
the gasket or o-ring (27) are in place before tightening screws (26)

- Install o-ring (49) into the seal carrier (44).

- Install lip seal (43) into the seal carrier (44) and secure using the retainer

clip (42).

- Install seal assembly (comprising parts 42, 43, 44, 49) into the rotorcase,

ensure anti-rotation lugs engage.

- Install o-ring (50) into the static seal seat (31).

- Install seal seat assembly (comprising parts 30, 31) to the rotorcase,

ensuring that the drive lugs and the drive slots engage.

- Install o-ring (32) into the rotary seal face (33).

- Install seal assembly (comprising parts 32, 33) into the rotor.

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

Page : 56

4.3.11 Strip Clean Single O-ring Seal
Fig 38

41

155

35

- Install o-ring (155) into the rotorcase (40).

Note: - During installing of the rotors to shafts care must be taken not
to damage or unseat the o-ring seal when inserting the rotor (41) into

o-ring (155).

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

40

109

Page : 57

4.3.12 Duralobe Single O-ring Seal OL1

Fig 39

- Install Sleeve (158) into the Rotorcase (40).

Press the sleeve in from the front of the rotorcase until flush with the back
face of the rotorcase.

Note:- Use Loctite 640 or a similar compound to seal the sleeve when
pressing in into the rotorcase – Also note that the sleeve is a press fit
so ensure that the sleeve is square when pressing it into the rotorcase.

- Install O-ring (155) into the Rotor (41).

- Install the rotor (41) onto the shaft making sure not to damage the o-ring

(155).

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

Page : 58

4.3.13 Duralobe Single O-ring Seal S2, S3, S4

Fig 41

- During Pump assembly fit the stop washers (160) to the rotorcase securing

with screws (26) tightening to correct torque, refer to section 5.2.

- Install O-rings (154) to Rotorcase sleeve (158).

- Install Sleeve assembly (comprising parts 154, 158) to Rotorcase (40).

Note:- that the sleeve is a press fit so ensure that the sleeve is square
when pressing it into the rotorcase and it is against the stop washers.

- Install O-ring (155) into the Rotor (41).

- Install the rotor (41) onto the shaft making sure not to damage the o-ring

(155).

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

Page : 59

4.3.14 MK2 Double O-ring Seal S1

Fig 40

Setting

Point

- Install Sleeve (158) into the Rotorcase (40).

Press the sleeve in from the front of the rotorcase and line the front of the
sleeve up with the end of chamfer see above setting point

Note:- Use Loctite 640 or a similar compound to seal the sleeve when
pressing in into the rotorcase – Also note that the sleeve is a press fit
so ensure that the sleeve is square when pressing it into the rotorcase.

- Install O-rings (155) into the Rotor (41).

Note:- When using the double seal ensure that the correct lubrcant is
used to lubricate the o-rings

- Install the rotor (41) onto the shaft making sure not to damage the o-ring

(155).

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

Page : 60

4.3.15 MK2 Double O-ring Seal S2, S3, S4

Fig 42

- During Pump assembly fit the stop washers (160) to the rotorcase securing

with screws (26) tightening to correct torque, refer to section 5.2.

- Install O-rings (154) onto the rotorcase sleeve (158).

- Install Sleeve assembly (comprising parts 154, 158) Into the

Rotorcase (40).

Note:- that the sleeve is a press fit so ensure that the sleeve is square

when pressing it into the rotorcase and it is against the stop washers.

- Install O-ring (155) onto the Rotor (41).

- Install the rotor (41) onto the shaft making sure not to damage the o-ring

(155).

- To disassemble reverse the above procedure.

- Before disassembling the seals, ensure pump is fully shutdown, refer to

section 3.5.

Page : 61

4.3.16 Flushed Product Seal

Auxiliary Services.

Every Duralobe® pump is provided with four seal flushing connections, two on
each side of the rotorcase, which are tapped 1/8" BSP.

There are two flushing connections for each seal, one for flush 'in', the other
for flush 'out', see fig 33 and the piping for the flush should be arranged to
provide an independent flush to each seal.

Pumps are supplied with blanking plugs in each flushing connection. If the
pump has been converted to a flushed product seal, these plugs can be
removed and the flush connections used to provide the appropriate flush.

Fig 33

Page : 62

i) Terminology.

WARNING

WARNING

a) "Quench"

- To provide a liquid barrier which is not induced to flow through the seal

area by any external means.

b) "Flush"

- To provide a liquid barrier which is induced to flow through the seal

area by an external means.

ii) Quench or Flush Media.

The media used for quenching or flushing a seal area must be fully compatible
with the pumped media, and the relevant materials of construction of the
pump.

Special consideration must be given to the temperature limitations of the
media to insure that no hazards are created, e.g. risk of fire or explosion.

iii) Single Mechanical Seal (For Low-Pressure Quench or Flush).

Refer to section 4.3.3.

This seal arrangement requires a supply of media to the outboard side of the
mechanical seal to quench or flush the seal area. The nature of the pumped
media and the specific duty conditions will determine whether a quench or a
flush is required.

A quench provides a static head. The quench media vessel should be
mounted a minimum of 1.5 feet above the pump, preferably directly above the
seal area. The interconnecting pipework should be as straight as possible,
avoiding horizontal runs, and with the minimum number of bends and
restrictions.

For a suitable flush, the media must be supplied at a flowrate of three litres
per minute per shaft seal (0.8 US Gal per min).

Note : The limiting flush or quench pressure in any application is 7 psi.

Page : 63

iv) Double Mechanical Seal (For High Pressure Flush).

WARNING

v) Double O-ring Seal (For High Pressure Flush).

WARNING

Refer to section 4.3.4.

This seal arrangement requires a supply of media to be circulated between
the inboard and outboard mechanical seals. The flush media must be supplied
at a flowrate of three litres per minute per shaft seal assembly (0.8 US Gal per
min). The flush pressure must be a minimum of 15 psi greater than the

maximum discharge pressure created by, or the maximum suction
pressure applied to, the pump, whichever is the greater.

Note : The limiting flush pressure in any application is 240 psi.

Refer to section 4.3.6.

This seal arrangement requires a supply of media to be circulated between
the inboard and outboard o-rings. The flush media must be supplied at a
flowrate of three litres per minute per shaft seal assembly (0.8 US Gal per
min). The flush pressure must be a minimum of 15 psi greater than the

maximum discharge pressure created by, or the maximum suction
pressure applied to, the pump, whichever is the greater.

Note : The limiting flush pressure in any application is 240 psi.

Page : 64

5.0 Specifications.

5.1 Clearance Chart

Bi-Wing Rotor Form

Multi-lobe Rotor Form

MAXIMUM

MODEL

S1S 15 300 9.0 - 10.0 6.0 - 12.7 9.0 - 15.0 7.0 - 13.0 3.5 - 3.9 2.4 - 5.0 3.5 - 5.9 2.8 - 5.1

S1M 10 300 9.0 - 10.0 6.0 - 15.0 9.0 - 15.0 7.0 - 13.0 3.5 - 3.9 2.4 - 5.9 3.5 - 5.9 2.8 - 5.1

S1L 7 300 11.0 - 12.0 8.0 - 15.9 12.0 - 18.0 11.0 - 16.0 4.3 - 4.7 3.1 - 6.3 4.7 - 7.1 4.3 - 6.3
S2S 15 300 14.0 - 16.0 12.0 - 20.6 13.0 - 21.0 15.0 - 22.0 5.5 - 6.3 4.7 - 8.1 5.1 - 8.3 5.9 - 8.7

S2M 10 300 14.0 - 16.0 13.0 - 22.3 13.0 - 21.0 15.0 - 22.0 5.5 - 6.3 5.1 - 8.8 5.1 - 8.3 5.9 - 8.7

S2l 7 300 15.0 - 17.0 13.0 - 24.2 17.0 - 25.0 18.0 - 26.0 5.9 - 6.7 5.1 - 9.5 6.7 - 9.8 7.1 - 10.2

S3S 15 300 19.0 - 21.0 18.0 - 28.0 20.0 - 30.0 21.0 - 29.0 7.5 - 8.3 7.1 - 11.0 7.9 - 11.8 8.3 - 11.4

S3M 10 300 20.0 - 22.0 18.0 - 30.0 20.0 - 30.0 21.0 - 29.0 7.9 - 8.7 7.1 - 11.8 7.9 - 11.8 8.3 - 11.4

S3L 7 300 20.0 - 23.0 19.0 - 32.0 24.0 - 33.0 25.0 - 33.0 7.9 - 9.1 7.5 - 12.6 9.4 - 13.0 9.8 - 13.0
S4S 15 300 26.0 - 30.0 25.0 - 40.0 30.0 - 43.0 32.0 - 40.0 10.2 - 11.8 9.8 - 15.7 11.8 - 16.9 12.6 - 15.7

S4M 10 300 29.0 - 33.0 27.0 - 42.0 30.0 - 43.0 32.0 - 40.0 11.4 - 13.0 10.6 - 16.5 11.8 - 16.9 12.6 - 15.7

S4L 7 300 30.0 - 35.0 27.0 - 44.0 34.0 - 47.0 36.0 - 44.0 11.8 - 13.8 10.6 - 17.3 13.4 - 18.5 14.2 - 17.3

Bar ° F A B C D A B C D

FRONT REAR TOP/SIDE MESH FRONT REAR TOP/SIDE MESH

MILLIMETERS (x 0.01) INCH (x 0.001)

*

Page : 65

5.2 Fasteners & Torque Settings.

Item

No.

Description Position

Socket Head

2

Cap Screw

Socket Head

7

Cap Screw

Lock Nut

(See 1.0) Size M20 x 1.0 M35 x 1.5 M45 x 1.5 M65 x 2.0

12

23

Cap Screw

Socket Head

Socket Head

Cap Screw

26

35 Retainer

Dome Nut

(Acorn)

36

37 Stud

Hammer Drive

56

110A

Screw

Socket Head

Cap Screw

110B

Cap Screw

Socket Head

Socket Head

Cap Screw

118

120

Cap Screw

Socket Head

Foot /

Rotorcase

Gearbox /

Rotorcase

Bearing /

Shaft

Bearing

Sleeve /

Rotorcase

Housing /

Rotorcase

Rotor /

Shaft

Front Cover

/ Rotorcase

Front Cover

/ Rotorcase

Nameplate /

Gearbox

RV Cylinder

/Front Cover

RV Cylinder

/Nut

RV Cylinder

/Front Cover

Piston RV

Head

Quantity /

Pump

Size M8 x 12 M10 x 16 M10 x 20 M16 x 25

Torque ft-lb

Quantity /

Pump

Size M6 x 30 M6 x 50 M10 x 50 M10 x 55

Torque ft-lb

Quantity /

Pump

Torque ft-lb

Quantity /

Pump

Size M6 x 22 M6 x 30 M12 x 50 M16 x 55

Torque ft-lb

Quantity /

Pump

Size M4 x 8 M5 x 12 M6 x 16 M6 x 20

Torque ft-lb

Quantity /

Pump

Torque ft-lb

Quantity /

Pump

Size M8 M10 M12 M12

Torque ft-lb

Quantity /

Pump

Size M8 x 35 M10 x 35 M12 x 52 M12 x 57

Torque ft-lb

Quantity /

Pump

Quantity /

Pump

Size M16 x 50

Torque ft-lb 40

Quantity /

Pump

Size M10 x 25

Torque ft-lb 80

Quantity /

Pump

Size M6 x 70 M6 x 80 M10 x 80 M16 x 110

Torque ft-lb 12 29 57 114

Quantity /

Pump

Size M10 x 55 M12 x 60 M16 x 55 M12 x 65

Torque ft-lb

S1 S2 S3 S4

444 4

29 57 57 133

444 8

12 29 57 57

222 2

0.75 – 1.11 1.46 – 1.85 2.21 – 2.58 4.06 – 4.43

666 6

12 29 100 133

88812

4 7.5 12 29

222 2

18 20 80 125

444 8

21 43 75 75

444 8

22 45 79 79

444 4

-

---

666 6

111 1

12 29 57 115

--

Notes: 1.0) Rolling torque quoted for nut, item 12 (reference section 4.2.1)

2.0) For position of items see section 5.6, typical basic pump build

8

10

Page : 66

5.3 Lubricants

Gearbox oil recommended for use with Duralobe® pumps is an “EP (Extreme
Pressure) grade gear lube” for the following ambient temperature ranges.

EP150 0 – 32°F
EP220 32 – 85°F
EP320 85°F and higher

Approximate pump gearbox capacities for Duralobe® pumps:

Always add oil to the level of the sight glass. The sight glass must be
located in the upermost position on the side of the gearbox cover. DO NOT
OVERFILL.

5.4 Material Specification.

Rotors 316 Stainless Steel

Rotorcase 316 Stainless Steel

Shafts 316 Stainless Steel

Front Cover 316 Stainless Steel

Rotor Retainer 316 Stainless Steel

Gearbox Cover Grade 220 Grey Cast Iron or 316 Stainless Steel

Bearing Sleeve 070 M20 Steel - S1, S2 & S3
220 Grey Cast Iron – S4

Pump
Model

S1 0.3 0.6 0.3 0.6
S2 1.1 2.4 1.1 2.4
S3 3 6.3 2.55 5.4
S4 7.55 16 5.7 12

(Suction and Discharge ports in)

Horizontal Plane Vertical Plane

liters

Mounting Attitude

US

liters

pints

US

pints

Page : 67

Page : 68

Dimensions in Millimetres

pp

MODEL

S1S

S1M

S1L
S2S

S2M

S2L
S3S

S3M

S3L
S4S

S4M

S4L

A B1 B2 B3 B4 B5 C D E F G HB HS HT J K L M N P Q R S T U V W X

25 85 85 99 99 99 84.5 176 17 16 j6 28 57 57 112 24 5 223 46 138 62 8 78 146 128 9 183 201 27.5 11.8

25 85 85 99 99 99 84.5 176 17 16 j6 28 57 57 112 24 5 232 53 138 62 8 78 146 128 9 183 201 27.5 12.1

25 85 85 99 99 99 84.5 176 17 16 j6 28 57 57 112 24 5 240 61 138 62 8 78 146 128 9 183 201 27.5 12.3

40 107 129 121 121 121 118 246 21 28 j6 42 75 75 160 38 8 317 65 197 90 14 117 197 170 11 255 282 42.5 34.0

50 107 129 121 121 121 118 246 21 28 j6 42 75 75 160 38 8 331 74 197 90 14 117 197 170 11 255 282 42.5 37.0

50 107 129 121 121 121 118 246 21 28 j6 42 75 75 160 38 8 345 87 197 90 14 117 197 170 11 255 282 42.5 39.0

50 131 153 145 145 145

80 131 163 145 153 158

80 131 163 145 153 158

80 178 210 192 200 205 216 442 30 60 m6 140 136 147 296 129 18 581 109 375 170 16 202 378 342 18 480 516 80.0 213.0

100 182 225 192 200 205 216 442 30 60 m6 140 136 147 296 129 18 612 127 375 170 16 202 378 342 18 480 516 80.0 237.0

100 182 225 192 200 205 216 442 30 60 m6 140 136 147 296 129 18 643 151 375 170 16 202 378 342 18 480 516 80.0 260.0

157.5

324 29 38 k6 80 100 100 215 70 10 435 83 274 124 14 152 243 214 13 329 358 57.5 80.0

157.5

324 29 38 k6 80 100 100 215 70 10 456 95 274 124 14 152 243 214 13 329 358 57.5 84.0

157.5

324 29 38 k6 80 100 100 215 70 10 480 115 274 124 14 152 243 214 13 329 358 57.5 88.0

Dimensions in Inches (except F and K)

Weight

(kgs)

MODEL

S1S

S1M

S1L
S2S

S2M

S2L
S3S

S3M

S3L
S4S

S4M

S4L

A B1 B2 B3 B4 B5 C D E

1.00 3.35 3.35 3.90 3.90 3.90 3.33 6.93 0.67 16 j6 1.10 2.24 2.24 4.41 0.94 5 8.78 1.81 5.43 2.44 0.31 3.07 5.75 5.04 0.35 7.20 7.91 1.08 26.0

1.00 3.35 3.35 3.90 3.90 3.90 3.33 6.93 0.67 16 j6 1.10 2.24 2.24 4.41 0.94 5 9.13 2.09 5.43 2.44 0.31 3.07 5.75 5.04 0.35 7.20 7.91 1.08 26.0

1.00 3.35 3.35 3.90 3.90 3.90 3.33 6.93 0.67 16 j6 1.10 2.24 2.24 4.41 0.94 5 9.45 2.40 5.43 2.44 0.31 3.07 5.75 5.04 0.35 7.20 7.91 1.08 27.0

1.50 4.21 5.08 4.76 4.76 4.76 4.65 9.69 0.83 28 j6 1.65 2.95 2.95 6.30 1.50 8 12.48 2.56 7.76 3.54 0.55 4.61 7.76 6.69 0.43 10.04 11.10 1.67 75.0

2.00 4.21 5.08 4.76 4.76 4.76 4.65 9.69 0.83 28 j6 1.65 2.95 2.95 6.30 1.50 8 13.03 2.91 7.76 3.54 0.55 4.61 7.76 6.69 0.43 10.04 11.10 1.67 81.0

2.00 4.21 5.08 4.76 4.76 4.76 4.65 9.69 0.83 28 j6 1.65 2.95 2.95 6.30 1.50 8 13.58 3.43 7.76 3.54 0.55 4.61 7.76 6.69 0.43 10.04 11.10 1.67 86.0

2.00 5.16 6.02 5.71 5.71 5.71 6.20 12.76 1.14 38 k6 3.15 3.94 3.94 8.46 2.76 10 17.13 3.27 10.79 4.88 0.55 5.98 9.57 8.43 0.51 12.95 14.09 2.26 176.0

3.00 5.16 6.42 5.71 6.02 6.22 6.20 12.76 1.14 38 k6 3.15 3.94 3.94 8.46 2.76 10 17.95 3.74 10.79 4.88 0.55 5.98 9.57 8.43 0.51 12.95 14.09 2.26 185.0

3.00 5.16 6.42 5.71 6.02 6.22 6.20 12.76 1.14 38 k6 3.15 3.94 3.94 8.46 2.76 10 18.90 4.53 10.79 4.88 0.55 5.98 9.57 8.43 0.51 12.95 14.09 2.26 194.0

3.00 7.01 8.27 7.56 7.87 8.07 8.50 17.40 1.18 60 m6 5.51 5.35 5.79 11.65 5.08 18 22.87 4.29 14.76 6.69 0.63 7.95 14.88 13.46 0.71 18.90 20.31 3.15 469.0

4.00 7.17 8.86 7.56 7.87 8.07 8.50 17.40 1.18 60 m6 5.51 5.35 5.79 11.65 5.08 18 24.09 5.00 14.76 6.69 0.63 7.95 14.88 13.46 0.71 18.90 20.31 3.15 522.0

4.00 7.17 8.86 7.56 7.87 8.07 8.50 17.40 1.18 60 m6 5.51 5.35 5.79 11.65 5.08 18 25.31 5.94 14.76 6.69 0.63 7.95 14.88 13.46 0.71 18.90 20.31 3.15 573.0

F

GHBHSHT J

(mm)

B1 applies for all threaded connections except BSPT and NPT
B2 applies for BSPT and NPT thread connections
B3 applies for all flange connections except ASA150, BS4504 and ASA300
B4 applies for ASA150 and BS4504 flange connections
B5 applies for ASA300 flange connections

Page : 69

K

(mm)

L M N P Q R S T U V W X

Notes: Dimensions given are for guidance only and should not

be used for installation purposes.
Certified dimensions will be su

lied on request

Weight

(lbs)

5.6 Typical Basic Pump Build.

Page : 70

5.7 Trouble Shooting.

Causes

EIZURE

NO FLOW

INCORRECT DIRECTION OF ROTATION. REVERSE MOTOR.

PUMP NOT PRIMED. EXPEL GAS FROM SUCTION LINE / PUMP CHAMBER & PRIME.

INSUFFICIENT NPSH AVAILABLE.

PRODUCT VAPORISING IN SUCTION LINE.

AIR ENTERING SUCTION LINE. REMAKE PIPEWORK JOINTS.

GAS IN SUCTION LINE. EXPEL GAS FROM SUCTION LINE / PUMP CHAMBER.

INSUFFICIENT STATIC SUCTION HEAD. RAISE PRODUCT LEVEL TO INCREASE STATIC SUCTION HEAD.

PRODUCT VISCOSITY TOO HIGH. DECREASE PUMP SPEED / INCREASE PRODUCT TEMPERATURE.

PRODUCT VISCOSITY TOO LOW. INCREASE PUMP SPEED / INCREASE PRODUCT TEMPERATURE.

PRODUCT TEMPERATURE TOO HIGH. COOL PRODUCT / PUMPING CHAMBER.

PRODUCT TEMPERATURE TOO LOW. HEAT PRODUCT / PUMPING CHAMBER.

UNEXPECTED SOLIDS IN PRODUCT CLEAN SYSTEM / FIT STRAINER ON SUCTION SIDE OF PUMP.

DISCHARGE PRESSURE TOO HIGH CHECK FOR BLOCKAGES / SIMPLIFY DISCHARGE LINE.

ROTORCASE STRAINED BY PIPEWORK. CHECK PIPE ALIGNMENT / SUPPORT PIPEWORK.

PUMP SPEED TOO HIGH DECREASE PUMP SPEED.

NDER CAPACITY

UMP OVERHEATS

RREGULAR FLOW

U

I

OTOR OVERHEATS

P

M

XCESSIVE SEAL WEAR

XCESSIVE ROTOR WEAR

E

E

S

OISE / VIBRATION

N

UP

UMP STALLS ON START

P

I

NCREASE SUCTION LINE & STATIC SUCTION HEAD DIAMETER.

SIMPLIFY SUCTION LINE & REDUCE LENGTH. REDUCE PUMP

SPEED & PRODUCT TEMPERATURE.

ACTION

PUMP SPEED TOO LOW INCREASE PUMP SPEED

SEAL FLUSH INADEQUATE INCREASE SEAL FLUSH TO REQUIRED PRESSURE / FLOW.

BEARING / TIMING GEAR WEAR REPLACE WORN COMPONENTS.

Page : 71

5.8 Typical Noise Emission Data.

Page : 72

5.9 Service History.

Pump Model: Pump Serial No:

Date Comments

Page : 73

5.10 Tool List.

Listed below are tools required for the maintenance of the Duralobe® pump.

TYPE SIZE OR RANGE S1 S2 S3 S4

COMBINATION WRENCH 13mm

COMBINATION WRENCH 17MM

COMBINATION WRENCH 19MM

COMBINATION WRENCH 24MM

HEXAGON (ALLEN) KEY 1/4"

HEXAGON (ALLEN) KEY 3/8"

HEXAGON (ALLEN) KEY 3MM

HEXAGON (ALLEN) KEY 4MM

HEXAGON (ALLEN) KEY 5MM

HEXAGON (ALLEN) KEY 6MM

HEXAGON (ALLEN) KEY 8MM

HEXAGON (ALLEN) KEY 10MM

HEXAGON (ALLEN) KEY 14MM

HEXAGON (ALLEN) KEY -

SOCKET DRIVEN

HEXAGON (ALLEN) KEY -

SOCKET DRIVEN

HEXAGON (ALLEN) KEY -

SOCKET DRIVEN

HEXAGON (ALLEN) KEY -

SOCKET DRIVEN

3MM

4MM

5MM

6MM

HEXAGON (ALLEN) KEY -

SOCKET DRIVEN

HEXAGON (ALLEN) KEY -

SOCKET DRIVEN

HEXAGON (ALLEN) KEY -

SOCKET DRIVEN

Page : 74

8MM

10MM

14MM

TYPE SIZE OR RANGE S1 S2 S3 S4

TORQUE WRENCH

TORQUE WRENCH

TORQUE WRENCH

TORQUE WRENCH

DEPTH MICROMETER 0 - 25 MM (0 - 1")

FEELER GAUGE SET

ROLLING TORQUE METER 0 - 5 NM (0 - 3.688 FT-LB)

ROLLING TORQUE METER 0 - 10 NM (0 - 7.376 FT-LB)

SOCKET FOR ROTOR

RETAINER

RELEASE BAR FOR SEAL

FACES

HOOK WRENCH

ADJUSTABLE UP TO MINIMUM 39

NM (28.765 FT-LB)

ADJUSTABLE UP TO MINIMUM 77

NM (56.792 FT-LB)

ADJUSTABLE UP TO MINIMUM 135

NM (99.571 FT-LB)

ADJUSTABLE UP TO MINIMUM 180

NM (132.761 FT-LB)

SUPPLIED WITH PUMP

SUPPLIED WITH PUMP

TO SUIT LOCKNUT OUTSIDE

DIAMETER 32MM (1.26")

HOOK WRENCH

HOOK WRENCH

HOOK WRENCH

SOFT-FACED MALLET

PIN PUNCH SMALL

STEEL HAMMER SMALL

FOR PUMPS WITH RELIEF VALVE INSTALLED

PRY BAR

PRY BAR

PRY BAR

TO SUIT LOCKNUT OUTSIDE

DIAMETER 52MM (2.047")

TO SUIT LOCKNUT OUTSIDE

DIAMETER 65MM (2.559")

TO SUIT LOCKNUT OUTSIDE

DIAMETER 85MM (3.346")

DIAMETER 8 200 LONG
(0.315" BY 7.874" LONG)

DIAMETER 13 400 LONG (0.512"

BY 15.748")

DIAMETER 16 600 LONG

(0.63" BY 23.622")

PIN WRENCH ADJUSTABLE

Page : 75

5.11 Notes.

The information contained in this document is correct at time of print,
but may be subject to change without prior notice.

Page : 76