MT184CP

Teaching material MT 184

Assembly and Maintenance Exercise: Piston Pump

10/2008

All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 10/2008

MT 184

ASSEMBLY AND MAINTENANCE EXERCISE: PISTON PUMP

Teaching material Dipl.-Ing. Klaus-Jürgen Radtke Dipl.-Geogr. Uta Linke

Version 1.0

Subject to technical alternations

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Table of Contents 1

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

2

Technological principles of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.1 Classification and categorisation of pump types based on operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2 Designs and operating characteristics. . . . . . . . . . . . . . . . . . . . . . . . . 5


2.3 GUNT Practice Line kits and their usage . . . . . . . . . . . . . . . . . . . . . . 8 2.4 Operating characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3

2.4.1

Pump and system characteristics . . . . . . . . . . . . . . . . . . . . . 15

2.4.2

Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.4.3

Alteration of the operating point by restriction and variation of speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4.4

Operating characteristics of multiple interacting pumps . . . . 20

2.4.5

Intake characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . 21

Basics of pump maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.1 Definition Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.2 Reasons for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.3 Detection of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3.4 Checking pumps and replacing common wearing parts . . . . . . . . . . 27 3.5 Wearing parts in the pumps from the GUNT Practice Line for assembly and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3.6 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.7 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.7.1

Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.7.2

Shaft and piston rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.7.3

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.7.4

Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Technical description of piston pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 4.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 4.2 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4.3 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 4.5 Dimensions of the piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51


4.6 Parts drawings and parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5

Assembly and dismantling of the piston pump. . . . . . . . . . . . . . . . . . . . . . 59 5.1 Assembly of the piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 5.1.1

Assembly phase 1 – Crankshaft (assembly unit 1). . . . . . . . 60

5.1.2

Assembly phase 2 – Connecting rod with piston rod (assembly unit 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.1.3

Assembly phase 3 – Packing gland (assembly unit 3) . . . . . 69

5.1.4

Assembly phase 4 – Intake valve (assembly unit 4) . . . . . . . 73

5.1.5

Assembly phase 5 – Pressure valve (assembly unit 5) . . . . 77

5.1.6

Assembly phase 6 – Gearbox (assembly unit 6) . . . . . . . . . 81

5.1.7

Assembly phase 7 – Pump housing (assembly unit 7) . . . . . 91

5.1.8

Assembly phase 8 – Pump . . . . . . . . . . . . . . . . . . . . . . . . . 100

5.2 Dismantling the piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 5.2.1

Dismantling assembly phase 8 – Pump . . . . . . . . . . . . . . . 107

5.2.2

Dismantling assembly phase 7 – Pump housing . . . . . . . . 110

5.2.3

Dismantling assembly phase 6 – Gearbox . . . . . . . . . . . . . 113

5.2.4

Dismantling assembly phase 5 – Pressure valve . . . . . . . . 116

5.2.5

Dismantling assembly phase 4 – Intake valve . . . . . . . . . . 117

5.2.6

Dismantling assembly phase 3 – Packing gland . . . . . . . . 118

5.2.7

Dismantling assembly phase 2 – Connecting rod with piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.2.8

Dismantling assembly phase 1 – Crankshaft . . . . . . . . . . . 120

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Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 6.1 Spare parts drawing and spare parts list . . . . . . . . . . . . . . . . . . . . . 123 6.2 Worksheet 1: Introduction to the piston pump, page 1 . . . . . . . . . . 130 6.3 Worksheet 2: Design, function and applications of the piston pump, page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 6.4 Worksheet 3: Identifying causes of faults, page 1 . . . . . . . . . . . . . . 135


6.5 Worksheet 4: Sealing systems, page 1 . . . . . . . . . . . . . . . . . . . . . . 136 6.6 Worksheet 5: Inspection of pumps, page 1 . . . . . . . . . . . . . . . . . . . 139 6.7 Worksheet 6: Servicing of pumps, page 1. . . . . . . . . . . . . . . . . . . . 141 6.8 Worksheet 7: Repairs to pumps, page 1 . . . . . . . . . . . . . . . . . . . . . 143 6.9 Worksheet 8: Wearing parts on the piston pump, page 1 . . . . . . . . 145 6.10 Worksheet 9: Assembling the piston pump, page 1 . . . . . . . . . . . . 147 6.11 Worksheet 10: Piston replacement, page 1. . . . . . . . . . . . . . . . . . . 153 6.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1 . . . . . . . . . . . . . . . . . . . 155 6.13 Worksheet 12: Spare parts ordering, page 1. . . . . . . . . . . . . . . . . . 163 7

Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 7.1 Spare parts drawing and spare parts list . . . . . . . . . . . . . . . . . . . . . 165 7.2 Worksheet 1: Introduction to the piston pump, page 1 . . . . . . . . . . 172 7.3 Worksheet 2: Design, function and applications of the piston pump, page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 7.4 Worksheet 3: Identifying causes of faults, page 1 . . . . . . . . . . . . . . 177 7.5 Worksheet 4: Sealing systems, page 1 . . . . . . . . . . . . . . . . . . . . . . 178 7.6 Worksheet 5: Inspection of pumps, page 1 . . . . . . . . . . . . . . . . . . . 181 7.7 Worksheet 6: Servicing of pumps, page 1. . . . . . . . . . . . . . . . . . . . 183 7.8 Worksheet 7: Repairs to pumps, page 1 . . . . . . . . . . . . . . . . . . . . . 185 7.9 Worksheet 8: Wearing parts on the piston pump, page 1 . . . . . . . . 187

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7.10 Worksheet 9: Assembling the piston pump, page 1 . . . . . . . . . . . . 189 7.11 Worksheet 10: Piston replacement, page 1. . . . . . . . . . . . . . . . . . . 195 7.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1 . . . . . . . . . . . . . . . . . . . 197 7.13 Worksheet 12: Spare parts ordering, page 1. . . . . . . . . . . . . . . . . . 205 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

9

Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209


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Introduction The MT 184 practice kit forms part of the GUNT learning concept for pump maintenance, which is designed to aid education and training at trade academies and corporate training centres. A close link between theory and practice is key to the learning content.


We offer the following products relating to the subject of pump assembly and maintenance: Pumps Code

Product

MT 180

Assembly and maintenance exercise - centrifugal pump

MT 181

Assembly and maintenance exercise - multi-stage centrifugal pump

MT 182

Assembly and maintenance exercise - screw pump

MT 183

Assembly and maintenance exercise - diaphragm pump

MT 184

Assembly and maintenance exercise - piston pump

MT 185

Assembly and maintenance exercise - in-line centrifugal pump

MT 186

Assembly and maintenance exercise - gear pump

Tab. 1.1

Product relating to pump assembly and maintenance

This kit includes a piston pump.

Groups of two or three students working with one kit represents an optimal way of learning.

1 Introduction

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The following learning content is covered: Learning content / Exercises Design and function of a piston pump Assembly and disassembly, including for maintenance purposes Replacing components (e.g. seals) Reading and understanding engineering drawings and operating instructions


Comparing different pumps (together with an additional kit forming part of this learning concept) Tab. 1.2

Learning content / Exercises

The teaching material includes a technical description detailing the basics of pumps and dealing with the related maintenance. The pump included in this kit is presented and described. Its assembly and disassembly is demonstrated. This section of the teaching material is intended to help tutors in preparing their own lessons. They may, of course, select information from it at their own discretion to use in their teaching. The kit also includes prepared exercise sheets for the students, followed by the relevant solutions. The appendix includes the complete set of drawings for the pump, in the form of an assembly drawing with parts list, and including all manufacturing drawings for the individual components.

We very much hope you enjoy using this GUNT assembly practice kit, and we wish you success in your important task of providing students and apprentices with an introduction to the basic principles of the technology.

1 Introduction

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Technological principles of pumps


This chapter is designed to provide basic information for the following assembly and maintenance exercises from GUNT. Code

Product

MT 180

Assembly and maintenance exercise - centrifugal pump

MT 181

Assembly and maintenance exercise - multi-stage centrifugal pump

MT 182

Assembly and maintenance exercise - screw pump

MT 183

Assembly and maintenance exercise - diaphragm pump

MT 184

Assembly and maintenance exercise - piston pump

MT 185

Assembly and maintenance exercise - in-line centrifugal pump

MT 186

Assembly and maintenance exercise - gear pump

Wherever liquids are transported, produced or required to be supplied, pumps are deployed. The demands which they must met vary widely. A vast range of fluids has to be conveyed, from highly sensitive pharmaceuticals, through large volumes of cooling liquid in power stations, to viscous chemical products. A wide variety of pumps have been developed over time for industrial applications. Not all pumps are mentioned in the following. Our outline presents a structured guide to the most common types of pump.

2 Technological principles of pumps

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2.1


Classification and categorisation of pump types based on operating principle Pumps are fluid-flow machines which dictate how processes operate - that is to say, they ensure that flow takes place within systems.


In practice, pumps are often named after the liquid they pump or their purpose, such as milk pumps or cooling pumps. However, technicians and fitters can more easily identify their design when they are named according to their operating principle.

Fluid-flow machines

Machines (Machine drives a flowing medium) Pumps

Positive-displacement pumps (Medium conveyed by displacement device)

Engines (Flowing medium drives machine) Turbines

Centrifugal pumps (A gyro causes centrifugal forces to act on the medium)

Oscillating Self-priming (Displacement device moves back and forth along an axis)

Rotating Self-priming (Displacement device rotates in the pump body)

Normally priming (Not carrying gas, pumping from low level restricted)

Self-priming (Carrying gas, pumping from low level possible)

Piston pumps

Gear pumps

Centrifugal pumps

Diaphragm pumps

Screw pumps

Multi-stage centrifugal pumps

Side-channel pumps

Inline pumps Fig. 2.1

Pump types


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2.2


Designs and operating characteristics The following table sets out the designs and operating characteristics of the most common positive-displacement pumps.

The piston pump incorporates an oscillating piston which is routed into a cylinder. The piston moves on an axis. The pump body is blocked by intake and pressure valves. A stroke gear drives the piston, which enlarges or reduces the pump chamber on every stroke. All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 10/2008

By enlarging the pump chamber, the pumped fluid is drawn in by way of the intake valve. After a change of stroke the pump chamber is reduced and the pumped liquid is displaced by way of the pressure valve. The diaphragm pump contains an elastomer diaphragm which is clamped into the pump housing. The oscillation is transferred from the stroke gear to the diaphragm by way of a thrust rod. The fluid feeds in and out by way of the valves, frequently executed as ball valves. The method of operation is the same as the piston pump, with the diaphragm acting as the displacement device. The gear pump contains two opposite rotating rigid or elastic gear wheels. The pump body is not closed off by valves. The liquid is pumped by the rotating gear wheels from the intake to the delivery side in the gaps between the teeth along the pump wall. The gear meshing and narrow gaps between the rotor and housing minimise the reflux.

The screw pump consists of two or more spindles with helical splines which rotate inside a correspondingly shaped housing. The pump body is not closed off by valves. The liquid is pumped axially in the free screw turns from the intake to the delivery side. Here too, as in the case of the gear pump, the sealing from the delivery to the intake side is provided by narrow gaps.


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The following table sets out the designs and operating characteristics of the most common centrifugal pumps.

The centrifugal pump contains a rotating, enclosed impeller with backward facing blades. The intake port is axially aligned to the pump shaft. The delivery port is aligned radially upwards.


The rotating impeller inside the pump body causes centrifugal forces to act on the pumped liquid. The liquid thrown out to the circumference of the pump by this flows out of the pump through the delivery port.

The multi-stage centrifugal pump is similar in design and action to the centrifugal pump. The difference is that is features multiple impeller arranged in a row on a shaft. The pumped liquid passes from the intake port via the rotating impeller through a fixed guide channel to the next impeller, and so on, until it reaches the delivery port. The multistage impeller layout means the pump attains higher delivery heads.

The inline centrifugal pump is similar in design and method of operation to the centrifugal pump. Its intake and delivery ports are along one axis however, though here too the feed to the pump flows axially by way of an appropriately shaped housing. The inline pump is used in straight pipelines.


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Other special centrifugal pump designs

The side-channel pump contains a rotating starshaped open impeller with radially running vanes. It rotates inside a pump housing featuring a side channel which narrows from the inlet to the outlet.


The energy transfer acts on the medium by means of an exchange flow of the liquid in the impeller with that in the side channel. The side channel pump thus operates continuously with a self-priming effect, whereas the centrifugal pump is not self-priming.

The canned motor pump is similar in design and action to the centrifugal pump. It is leakage-free, as it requires no shaft seal. The drive of the canned motor pump is located practically inside the pump housing, and the pumped liquid flows around it.

The magnetic clutch pump is similar in design and action to the centrifugal pump. It is leakage-free and requires no shaft seal. The magnetic clutch pump is driven by a non-contact magnetic clutch. The magnet on the pump shaft is inside the pump housing. It is separated from the magnet on the motor shaft by a tube.


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2.3


GUNT Practice Line kits and their usage The GUNT Practice Line kits for assembly and maintenance exercises include the following pumps:


MT 180 – Centrifugal pump

Fig. 2.2

Toolkit with parts set and pump

Fig. 2.3

Sectional drawing of the centrifugal pump

Centrifugal pumps are in widespread use, and are primarily used to pump fluid media. Their applications include in shipbuilding, industry and water supply.


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MT 181 – Multi-stage centrifugal pump

Fig. 2.4


Fig. 2.5

Sectional drawing of a similar multi-stage centrifugal pump

The multi-stage centrifugal pump is modular in design, and is used to pump fluid media at higher delivery pressures. It is used in water supply and in industry.


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MT 182 – Screw pump

Fig. 2.6


Fig. 2.7

Exploded-view drawing of the screw pump

Screw pumps are primarily used to transport viscous media such as lubricating oil, plant oil, glycols and polymers. Their applications include lubrication systems for diesel engines and transmissions, as well as in hydraulic systems.


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MT 183 – Diaphragm pump

Fig. 2.8


Fig. 2.9

Sectional drawing of the diaphragm pump

Diaphragm pumps are absolutely leakage-free and, provided appropriate materials are selected, are particularly well suited to pumping aggressive fluids such as acids and caustic in chemical engineering applications. Diaphragm pumps are often used for volumetric metering, as metering pumps.


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MT 184 – Piston pump

Fig. 2.10


Fig. 2.11

Drawing of the piston pump

Piston pumps are used primarily to transport fluids at high delivery pressures and low flow rates. Typical applications include pumping drinking water and domestic water in residential areas, in agriculture, onboard ships and in industry.


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MT 185 – Inline centrifugal pump

Fig. 2.12


Fig. 2.13

Exploded-view drawing of the in-line centrifugal pump

In-line centrifugal pumps are a sub-category of centrifugal pumps. Inline pumps are installed in straight pipelines. They are required in applications including water supply, watering and sprinkler systems, and in heating engineering.


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MT 186 – Gear pump

Fig. 2.14


Fig. 2.15

Exploded-view drawing of the gear pump

Gear pumps are of the rotating positive-displacement pump category, and are characterised by pulsation-free delivery at operating pressures up to 40bar. High-viscosity media such as oils, paints and adhesives can be pumped.


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2.4


Operating characteristics of pumps Alongside preventive maintenance, repair work forms a key part of general service operations. Damage to pumps can be traced back to incorrect operation in more than 50% of cases. It is advantageous for the assembly personnel to have basic knowledge of how the pump operates and are aware of how to use the pump correctly.

Pump and system characteristics The delivery capacity of a pump is indicated by the pump’s characteristic curve. The delivery rates are measured on the test stand at the respective delivery pressures. The pump measurement data is depicted in the form of a characteristic curve. Usually the delivery head is given in place of the delivery pressure (as a result the characteristic curves of centrifugal pumps are not dependent on the density of the pumped liquid).

Head H

In the case of centrifugal pumps the dependency of the delivery rate on the head is marked: As the head rises, the delivery rate decreases significantly. By contrast, the delivery rate of positive-displacement pumps remains virtually constant as the head rises. Head H


2.4.1

Delivery Q Fig. 2.16

Characteristic curve for a centrifugal pump


Characteristic curve for a positive-displacement pump

In the case of positive-displacement pumps, it must be ensured that the permissible operating pressure is not exceeded. Overflow valves are frequently used for this.


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Operation of the positive-displacement pump with the overflow valve (partially) open is depicted in the horizontal segment of the curve (see Fig. 2.17). The graph gives an indication of the delivery capacity of the pumps, though it provides no information on the delivery data actually achieved.

The system operating data can likewise be measured and depicted graphically in the system characteristic curve. As the delivery rate increases, the system pressure - determined by practical calculation - rises. Head H


An often cited problem when operating pumps is that the pump does not reach the necessary pressure. Generally speaking, pumps only deliver material; the associated pressure is caused by the system.


System characteristic curve


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2.4.2


Operating point The actual delivery data result from the interaction of the pump and the system.


1

Head H

Head H

If the pump and system curves are plotted on the same diagram, the point at which the curves intersect is the operating point.

1 Delivery Q Fig. 2.19

Operating point (1) of a normally priming centrifugal pump


Operating point (1) of a positive-displacement pump

So if the operating data do not conform to the specification, the technician should first check and calculate the correct operation of the pump in the system. This should be done on initial commissioning and every time the system is modified.


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2.4.3


Alteration of the operating point by restriction and variation of speed

Head H

While the delivery rate decreases as the head rises on a centrifugal pump, the delivery of a positive-displacement pump remains constant as the pressure rises.

Head H


In practice, restriction is frequently used to set the desired delivery rate. The flow is restricted by partially closing a valve on the delivery side of the pump. This results in a new system curve with a steeper rise. The new operating point 2 is the point of intersection of the new system curve with the pump curve. Or in other words: The operating point has shifted along the pump curve from 1 to 2.

2

2

1

1 Delivery Q Fig. 2.21

Shift in operating point from (1) to (2) by restriction for a normally priming centrifugal pump



Shift in operating point from (1) to (2) by restriction for a positive-displacement pump

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A common method of shifting the operating point of a pump is to vary the speed. The speed is varied by means of an adjuster gear or a frequency inverter. This produces a new pump characteristic curve. The diagrams show an increase in speed from n1 to n2 for both pump types (see Fig. 2.23 and Fig. 2.24). In the case of the centrifugal pump, the pump curve moves upwards, while for the positive-displacement pump it shifts to the right.

Head H

Head H


In both diagrams the operating point shifts upwards along the system curve. That is to say, higher heads and delivery rates are produced as the speed increases.

n2 n2

n1 n1 Delivery Q Fig. 2.23

Influence on the pump characteristic of a variation in speed for a normally priming centrifugal pump



Influence on the pump characteristic of a variation in speed for a positivedisplacement pump

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2.4.4


Operating characteristics of multiple interacting pumps Operation of multiple pumps simultaneously in a system is quite common, and in many cases essential in order to conform to extreme operating specifications.


If multiple pumps are configured in parallel, the delivery rate is increased. If pumps are configured in series (one behind the other), the delivery heads are added together.

Fig. 2.25

Parallel configuration

Fig. 2.26

Series configuration

The pump industry has made use of these properties and developed a number of designs accordingly. Multi-flow pumps achieve high delivery rates, multi-stage pumps achieve high heads.

Fig. 2.27

Multi-flow pump, sectional view and delivery principle


Fig. 2.28

Multiple-stage pump, sectional view and delivery principle

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2.4.5


Intake characteristics of pumps Attention must be paid to the intake characteristics of the pumps. A distinction is made between selfpriming and nonselfpriming pumps.


The normally priming centrifugal pump is a non-self-priming pump. It is not capable of pumping a gaseous medium out of the pump body. It must always be ensured that a liquid is fed in from a higher level, or where the feed is from a lower level, the liquid head does not collapse, such as due to the use of foot valves on the intake side.

Fig. 2.29

Infeed of a pump system for a normally priming pump


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Self-priming pumps include side channel pumps (see chapter 2.2, page 5). They are capable of pumping gases. However, the pump body must always be filled with liquid for this to happen. That is why the intake and delivery ports on side channel pumps always point upwards.

Fig. 2.30

Intake of a pump system for a self-priming pump

Most positive-displacement pumps are self-priming. The displacement device is able to compress the gas and displace it out of the pump body. For this to happen, however, the pump must be partially filled with liquid, because only wetted valves close exactly such that no reflux is possible. This also applies to rotating positive-displacement pumps, of which the wetted gaps restrict reflux.


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3

Basics of pump maintenance

3.1

Definition Maintenance


All pump operators should maintain their pumps in accordance with the maintenance and operating instructions issued by the manufacturers. Maintenance is the umbrella term for inspection, servicing and repair (see Fig. 3.1). A log book or machine file should be set up for each pump unit, indicating the current status and the repair work carried out to date.

MAINTENANCE TO DIN 31051

Inspection

Servicing

Repairs

Recording and assessment of the current actual status

Preservation of the specified status

Restoration of the specified status

Measurement, Testing, Diagnosis

Cleaning, Lubrication, Adjustment

Replacement, Correction

With the system running and at stand still based on inspection instructions

Only with system stopped according to maintenance instructions

Only with the system stopped, based on specific work order and after careful preparation

Fig. 3.1

Maintenance

3 Basics of pump maintenance

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3.2


Reasons for maintenance Pumps are required for the operations of many manufacturing systems. If the pumps are malfunctioning, there is a risk of production outages. Appropriate maintenance is a key factor determining the productivity of operations.

• The cost of purchasing a mid-sized industrial pump is considerable. The annual cost of wearing parts amounts to around 10% - 20% of the purchase price of the new pump. • Holding a complete replacement pump in stock is inefficient and expensive for many businesses. It is, however affordable, and advisable, to hold stocks of key pump spares. • The delivery lead times for complete pumps are usually lengthy, whereas spares can be supplied from suppliers’ central stores at short notice.

1

Cost


Complete replacement of the pump is possible in the event of a defect, though it is not always essential and, especially, is not necessarily cost-effective. Carrying out preventive maintenance and servicing, as well as repairs, is advantageous. A number of reasons are cited by way of example.

2

Service life Fig. 3.2

Total cost, comparison of replacement (1) and maintenance (2)

• Fig. 3.2 shows that routine maintenance of pumps (2) results in lower costs in the medium and long term than complete replacement of pumps (1).


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3.3


Detection of faults Many factors need to be considered in order to ensure optimised, trouble-free operation of pumps. Nevertheless, faults will routinely occur. A number of basic points need to be observed in order to assess faults and their causes:


• The specifications of the delivery medium need to be considered in order to ensure long service life of the pumps. The material durability of the pump components and seals must be ensured. The design and construction of the pump must be attuned to the specific pumping requirements. • Most pumps are driven by electric motors. Attention must be paid to correct dimensioning and selection. • Incorrect electrical connections and setting the incorrect direction of rotation are often sources of faults resulting in production problems. • As a general rule applicable to all pumps, lengthy periods of dry running should be avoided, as this would substantially shorten the service lives of the shaft seal, piston seal and valves. The delivery medium provides additional lubrication of those components. This principle is illustrated by the example of the floating ring seal in Fig. 3.3.

Fig. 3.3

Floating ring seal with liquid film

There must always be a liquid film between the contact faces of a floating ring seal.


25

10/2008

MT 184


During inspection of the pump, checks should be made regularly while the pump is running to ensure early detection of faults, focussing in particular on the following points: • Leakage • Noise • Smooth running • Temperature • General condition All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 10/2008

The reasons for pump faults are many and varied. System-related disturbances such as pressure surges should be avoided or eliminated. Incorrectly switching system valves may stop the pumped liquid to an extreme degree, causing overlaid liquid waves to form which result in pressure surging as far as into the pump. Trapped foreign bodies cause significant damage inside the pump. Deformed shafts, destroyed bearings and valves, as well as scraping impellers, are the consequences of such disturbances. Even tiny abrasive particles will cause long-term damage to the pump and the seals. The occurrence of cavitation is a system fault which needs to be prevented. If the infeed line to the pump is incorrectly dimensioned, it is possible that a vacuum will created in the intake port, causing the medium to boil. The increase in pressure in the pump causes the boiling bubbles to implode, thereby destroying the housing and impeller.

Fig. 3.4

Cavitation damage to a pump impeller


26

10/2008

MT 184

3.4


Checking pumps and replacing common wearing parts In accordance with the service intervals specified in the manufacturers’ maintenance instructions, which are additionally dependent on the specific operating conditions, it is advisable to check pumps about once a year.

Bearings


The operating instructions specify that the lubricant should be changed on pumps with an enclosed gear and bearing unit. Modern-day greased bearings are lifetime-lubricated, and merely need to be checked for smooth running.

Shaft seals Packing glands and floating ring seals are checked for leaks and wear. Glands can be adjusted, if still possible. The gland packing should be replaced after about 2000 operating hours. The service lives of the floating ring seals are considerably longer. They are replaced in full if worn.

Couplings Pumps coupled to their drives by flexible couplings should be checked for flush coupling. The power-transmitting components should be checked for wear and replaced as necessary.


27

10/2008

MT 184


Pump internals The pumps should be opened and their internals checked for wear and corrosion at the specified servicing intervals. In the case of centrifugal pumps, as well as the shaft seal the static seal ring must be checked and replaced if worn.


The valves of reciprocating pumps, including their sealing faces, should be checked. Piston rings and packing should be checked for wear, and the plungers and sleeves checked for scoring.

Pump internals

20

Shaft seal Bearing

Fig. 3.5

Coupling

Pump unit with listed wearing part groups


28

10/2008

MT 184

3.5


Wearing parts in the pumps from the GUNT Practice Line for assembly and maintenance It should be stated by way of preamble that, according to the state of the art in centrifugal pumps, bearings are no longer classed as wearing parts. MT 180 – Centrifugal pump


Housing seal

Fig. 3.6

Shaft seal (gland)

Sectional drawing of the centrifugal pump

MT 181 – Multi-stage centrifugal pump Packing gland

Fig. 3.7

Housing/stage seal

Floating ring seal

Sectional drawing of a similar multi-stage centrifugal pump


29

10/2008

MT 184


MT 182 – Screw pump


Housing seal

Housing seal

Floating ring seal Fig. 3.8

Exploded-view drawing of the screw pump

MT 183 – Diaphragm pump

Valves

Diaphragm Oil filling Fig. 3.9

Journal bearing

Sectional drawing of the diaphragm pump

The wearing parts mentioned should be replaced during servicing.


30

10/2008

MT 184


MT 184 – Piston pump

Piston rod seal


Valves

Oil filling Fig. 3.10

Piston seal Drawing of the piston pump

MT 185 – Inline centrifugal pump

Housing seal Fig. 3.11

Floating ring seal

Exploded-view drawing of the in-line centrifugal pump

Wear is to be expected on the parts marked, necessitating replacement of them.


31

10/2008

MT 184


MT 186 – Gear pump

O-rings


Floating ring seal

Wear disc Fig. 3.12

Journal bearing

Housing seal

Sectional drawing of the gear pump

Any well organised maintenance department should hold stocks of the wearing parts on the various pumps mentioned in this chapter.


32

10/2008

MT 184

3.6


Shutdown


In systems in which uninterrupted running of pumps is extremely important, such as in power stations or onboard ships, replacement units are installed fully piped-up as standby units. This allows servicing or repairs to be carried out during live operation, by switching to the standby unit.

Fig. 3.13

Installation with standby pump

Fig. 3.14

Single pump with stop valves

In most production environments, maintenance can only be carried out during production downtimes - that is, at partial or complete standstill. The pumps should be integrated into the system in such a way that short-interval servicing can be carried out without removing them. That is to say, they must be easily accessible for inspection and servicing. On the pump intake side and the delivery side stop valves should be installed. In the case of positive-displacement pumps, the drive unit is first shut down. Immediately after the pump stops the delivery-side valve is closed, then the intake side is closed. If non-return valves are installed, they automatically act as stop valves. So installed non-return valves on the delivery side, for example, prevent possible reflux to the pump. In the case of centrifugal pumps, the delivery-side valve is first closed, then the drive is shut down, and then the intake side is closed. Before opening the pump, the pump and the connected piping system must be drained. This can be done either by way of sealing plugs or by carefully detaching the pipe fittings. If the pump unit is removed completely from the system for major maintenance work, the safety guidelines issued by the drive manufacturers must additionally be followed.


33

10/2008

MT 184

3.7


Repairs Whereas during servicing parts are usually replaced following checking and as required, during repair complete wearing parts or defective components are replaced after predetermined operating cycles. These cycles are either specified by the manufacturers or they are determined by the identified condition of parts at the various maintenance intervals.


It is advisable to schedule every second to third service as a repair operation.

3.7.1

Static seals Flat seals and O-rings used for sealing between metal components and to prevent escape of liquid from the pump body are replaced completely. Their locations include at the connection fittings and on the housing covers, floating ring seals, shaft sleeves and valves. Procedure: • Dismount the pump • Remove the seals and dispose of them • Clean the parts • Install the new seals during reassembly • Avoid mechanical damage. Ensure cleanliness. Grease seals where necessary.


34

10/2008

MT 184


Static seal

Static seals


Static seals

Fig. 3.15

O-rings in a centrifugal pump


35

10/2008

MT 184

3.7.2


Shaft and piston rod seals


The most varied stresses on seals in pump engineering occur in the sealing of shaft and piston rod feed-throughs. These seals must act between areas subject to different pressures, and are subject to the demands of a wide variety of media, as well as having to withstand additional physical strains caused by rotating shafts or oscillating piston rods. These types of seal are known in engineering as dynamic seals. Operators expect reliable sealing, with minimal leakage, over a long service life. The shaft seals in particular should be preventively replaced during scheduled repair work, because of the extreme stresses to which they are subject.

Piston rod seal Fig. 3.16

Example of a piston rod seal

Shaft seal

Fig. 3.17

Example of a shaft seal


36

10/2008

MT 184


A tried and proven method of sealing shafts is by means of soft packing glands. This packing consists of a woven cord made principally of solid fabrics which is inserted in the packing space between the shaft and the housing, where it is deformed by an axial force and so moulded to the surfaces it is intended to seal. 1

3


4

2

Fig. 3.18

Example of a gland

Fig. 3.19

Packing gland packing

To seal the pump shaft, packing glands (1) are used. These are provided in a wide range of materials and designs depending on the pump application. To protect the shaft, a shaft sleeve (2) is installed. Locking rings or ancillary glands (3) hold the packing in place. The gland press (4) compresses the packing by way of screw fittings. Correct functioning demands careful assembly and commissioning.


37

10/2008


MT 184


Fig. 3.20

Item

Name

1

Washer

2

Shaft

3

Packing gland packing

4

Locking ring

5

Packing gland press

6

Stud bolt with hexagonal nut

7

Shaft sleeve

8

Housing cover

Packing gland of a centrifugal pump, sectional view with zoom

When packing a new gland the following points need to be considered: • Correct choice of packing based on quality and dimensions • Completely remove old packing residues (3) • The shaft protective sleeve (7) must be free of surface damage • Insert the packing (3) with offset interfaces • Use of sharp tools will damage the gland • Tighten the gland press (5) by screws after inserting the packing, then slacken it slightly • The pump shaft (2) must be loose enough to be turned slightly by hand


38

10/2008

MT 184


• Only tighten up the gland press after a run-in time of about 20-30 minutes with leakage of 50-100 drops per minute


• Adjust the gland to the required leakage rate of 3 drops per minute

To seal shaft lead-throughs which are subject to high stresses, floating ring seals are the most advantageous option nowadays. They are available in a wide range of designs, dimensions and frictional material pairings. Correctly selected, fitted and operated floating ring seals will permit longer-lasting operation of rotating positive-displacement and centrifugal pumps, with less leakage, then packing glands. 3

Fig. 3.21

2

4

1

Drawing of a floating ring seal

Floating ring seals are contact seals which create a yielding seal connection between stationary and rotating contact faces. Between the contact faces is a film of liquid, which assumes a stable position due to the centrifugal force occurring during rotation. The floating ring seal is sealed against the housing by means of static elastomer seals (1). The floating ring (2) rotating with the shaft is held axially in place relative to the counter-ring (4) fixed in the housing by a spring (3). The contact faces thus automatically adjust axially. Even high pressures can be controlled by means of hydraulic relief.


39

10/2008

MT 184



Fig. 3.22

Floating ring seal

Procedure for replacing the floating ring seal on a centrifugal pump shown below: • Shut down the pump • Open the pump cover (1) • Slacken the impeller nut (2) • Detach the impeller (3) from the shaft • Remove the floating ring (4) from the shaft • Pull the counter-ring (5) out of the housing using a suitable implement • Assemble in the reverse order of removal

1 3

4

5

2

Fig. 3.23

Example of replacing a floating ring seal on a centrifugal pump


40

10/2008

MT 184


In view of the wide range of floating ring seal designs and pump versions, methods of removal and fitting vary. The principle illustrated here is that applicable to the most frequently used centrifugal pump.


The piston rod sealing in oscillating motions of the piston rods and plungers of the piston pumps is achieved by using packing glands, lipped rings, grooved rings (1) and conical rings held in support rings (2). The design and materials must always be selected to match the given operating conditions. Spring-loaded (3) seals, for example, offer uniform pre-tension, low friction and so longer service lives. 3

Fig. 3.24

1

2

Drawing of a piston rod seal

The method of removal and fitting depends on the specific pump version and design. The manufacturers’ fitting instructions are useful in this context, and should be followed.


41

10/2008

MT 184



The same is true of the piston seals. Replacing piston rings and piston sleeves forms part of the essential scheduled repair routine. Some design variants are shown in Fig. 3.25.

Piston with hemp stricks

Fig. 3.25

Piston with leather/rubber sleeves

Piston with metal seal rings

Examples of piston seals


42

10/2008

MT 184

3.7.3


Valves Positive-displacement pumps such as reciprocating pumps and diaphragm pumps seal off the delivery space by means of intake and delivery side pressure valves. They open due to the resultant pressure difference on every stroke and close due to their intrinsic mass or by additional spring force.


The valves of the smaller diaphragm pumps, used as metering pumps in the chemical industry, are executed as ball valves. Owing to the more precise effect achieved, twin ball valves are often installed. They are replaced by simply unscrewing the valve unit out of the housing.

Fig. 3.26

Twin ball valve of a diaphragm pump

The valves of the piston pumps may be executed as weight or spring-loaded disc valves. The sealing faces are mostly metallic, and correspondingly sensitive. After being individually removed, the discs are replaced. The valve seats are checked and re-milled or lapped as necessary. In the case of valves with an additional elastomer sealing disc, only the disc needs to be replaced, and the smooth running checked.


43

10/2008

MT 184



Weighted with conical seat

Fig. 3.27

3.7.4

Spring-loaded with flat seat and seal ring

Spring-loaded with flat seat

Examples of disc valves

Spare parts ordering Maintenance work should generally be carried out on a routine basis in accordance with the maintenance instructions and safety rules laid down by the manufacturers. Key parts should be replaced at the maintenance intervals indicated in the operational or machine log. Arrangements should be made for parts to be procured from the supplier in advance. Every pump has a rating plate affixed to it by the manufacturer. The rating plate indicates the manufacturer’s name, the pump model and serial number. The data is often also imprinted on the housing, so the information is still available even if the rating plate comes off. Based on this information, the exact technical and material specification can be identified.


44

10/2008

MT 184



Fig. 3.28

Example of a housing with imprinted model and serial number

The details shown in Fig. 3.29 need to be quoted to the supplier when ordering spares, so as to ensure the correct parts are supplied:

1. Pump model 2. Serial number 3. Part name 4. Item number on parts list

Fig. 3.29

Information for spare parts ordering, e.g. identified from rating plate, parts drawing or parts list


45

10/2008


MT 184


4

Technical description of piston pump

4.1

Description

Fig. 4.1

Piston pump

Piston pumps are used primarily to transport fluids at high delivery pressures and low flow rates. At constant speed, the volumetric flow also remains constant at different pressures. A air chamber built-in to the pump damps the pressure spikes which occur on each stroke. The pump presented here is a double-acting piston pump, which means that each stroke is simultaneously an intake and a delivery stroke. The pump incorporates a safety valve, so that if the pressure rises too high a portion of the flow is returned to the intake side. Typical applications of piston pumps include pumping drinking water and domestic water in residential areas, in agriculture, onboard ships and in industry and at commercial garden centres.

4 Technical description of piston pump

46

10/2008

MT 184

4.2


Mode of operation


The piston pump is driven by way of a pulley and a V-belt by an electric motor. On every revolution, the crankshaft acts by way of the connecting rod and the crosshead on the piston (1) which is mounted on the end of the piston rod. This stroke motion causes the piston to move back and forth in the cylinder bushing (2). On every stroke the piston (1) enlarges and reduces the size of the delivery chamber. In the enlarging delivery chamber a negative pressure is created, causing the pressure valve (3) to close and liquid to flow via the intake valve (4) into the delivery chamber. In the reducing delivery chamber the piston presses the liquid via the pressure valve out of the pump body, while the intake valve is pressed closed. The piston pump investigated here has a delivery chamber on each side of the cylinder bushing. The pump is doubleacting, since on every stroke it simultaneously draws in on one side and displaces on the other. If the pressure on the delivery side (5) of the pumps is too high, the built-in safety valve (7) opens and the liquid flows inside the pump back to the intake side (6).

2

Item

Name

1

Piston

2

Cylinder bushing

3

Pressure valve

4

Intake valve

3 1

4

Fig. 4.2

Delivery principle of a double-acting piston pump


47

10/2008

MT 184


7


5

6

3

Fig. 4.3

4

Item

Name

3

Pressure valve

4

Intake valve

5

Delivery Side

6

Intake side

7

Safety valve

Delivery principle of the piston pump

The piston pump is self-priming. It must, however, be primed prior to initial commissioning. The pump delivery is independent of the direction of rotation of the drive. However, optimum lubrication of the gearbox can only be effected in the direction indicated by the arrow on the pump.


48

10/2008

MT 184

4.3


Layout The layout of the piston pump is shown in the drawings (see chapter 9, page 209). The pump consists of the following main components: • Air chamber with safety valve • Pump housing with valves • Piston • Gland


• Crankshaft • Crosshead • Piston rod • Gearbox housing

1

5

6

7

4 2

8

3

Fig. 4.4

Item

Name

Item

Name

1

Air chamber with safety valve

5

Crankshaft

2

Pump housing with valves

6

Crosshead

3

Piston

7

Piston Rod

4

Packing gland

8

Gearbox housing

Component assemblies of the piston pump


49

10/2008

MT 184


The motor is mounted on the pump unit by clamp rails. The crankshaft, the connecting rod and the crosshead are automatically lubricated in the gearbox housing by circulating oil on every rotation. The piston rod is sealed off from the delivery chamber by a packing gland. The sleeved piston made of NBR rubber runs in a stainless steel cylinder bushing.


The two delivery chambers each contain two disk valves with valve rubber plates. The delivery side of the pump is executed as a air chamber, with a built-in safety valve. 4.4

Technical data Pump model: Power consumption: Max. capacity: Max. delivery pressure: Motor speed: (driven by V-belt) Intake connection: Pressure connection: Pump materials: Pump body: Valves: Cylinder bushing: Piston: Piston rod seal:


PM 10 max. 0,37 1000 6 1450

kW ltr/h bar rpm

1 “ 1 “ GG20 Brass (CuZn39Pb3) X6CrNi18-10 NBR PTFE saturated packing rings

50

10/2008

MT 184


4.5


Dimensions of the piston pump

Fig. 4.5

Dimensions


51

10/2008

MT 184

Parts drawings and parts lists

85, 86 79, 80 87 84, 85 81, 82

79, 80 83, 87


8

4.6


Fig. 4.6

Spare parts drawing for the piston pump


52

10/2008

MT 184


11 19

4, 23

6 3 - 15

22


21

16

7 1 30,31 24 25 5 26 28 13

29

9

27 12

32 2 33 18 17

35 34

14

10 20 8

Fig. 4.7

Spare parts drawings for the gearbox


53

57

42 58

Fig. 4.8

4 Technical description of piston pump 44

60

36

64

51 38 49 37

40

43

59

70

71

54 68

39

50, 52, 53

41

69

58 66

67 47

73 74

72

62

48

47

75 46, 77 76

65

61

MT 184

63

45


10/2008


Spare parts drawings for the pump housing

54

10/2008


MT 184


Item

Quanti ty

Unit

Name

Item number / Standard

1

1

Piece

Connecting rod

MT184.10.04.001

2

1

Piece

Packing gland housing

MT184.10.05.002

3

1

Piece

Crankshaft

MT184.10.03.001

4

1

Piece

Bearing cover, open

MT184.10.10.001

5

1

Piece

Gearbox housing

MT184.10.09.001

EN-GJL-200

6

1

Piece

Bearing cover, closed

MT184.10.09.002

EN-GJL-200

7

1

Piece

Gearbox cover

MT184.10.09.003

DOC04

8

1

Piece

Base plate

MT184.10.09.004

S235JR

9

1

Piece

Oil splash guard

MT184.10.09.005

DOC04

10

1

Piece

Packing gland seal

MT184.10.09.006

SBR/B-870M

11

2

Piece

Bearing cover seal

MT184.10.09.007

SBR/B-870M

12

1

Piece

Oil stripper

MT184.10.09.008

60NBR693 SW

13

1

Piece

Oil plug

MT184.10.09.009

CuZn39Pb3

14

1

Piece

Duo-piston

PM10

Simirit

15

1

Piece

Disk spring

DIN 6888-5x7,5

16

8

Piece

Hexagon nut

ISO 4032-M6

8

17

2

Piece

Hexagon nut

ISO 4032-M8

8

18

1

Piece

Spring ring

DIN 127-A-8

A2

19

6

Piece

Hexagon screw

ISO 4017-M6x12

8.8

20

4

Piece

Rubber buffer

500029

GMT

21

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

22

2

Piece

Angled oiler with nut

G1/8

Spike

23

1

Piece

Radial shaft seal

DIN 3760-A16x35x7

NBR

24

2

Piece

Grooved ball bearing

DIN 625-6202

25

1

Piece


DIN 625-6203

Tab. 4.1

Comments

Spare parts list


55

10/2008


MT 184


Item

Quanti ty

Unit

Name


Comments

26

1

Piece

Crosshead

MT184.10.04.002

EN-GJL-200

27

1

Piece

Piston Rod

MT184.10.04.003

X14CrMoS17

28

1

Piece

Straight pin

ISO 8734-12x35

C1

29

1

Piece

Hexagon nut

ISO 4032-M8

8-A2

30

1

Piece

Hexagon screw

ISO 4017-M6x25

8.8

31

1

Piece

Hexagon nut

ISO 4032-M6

8-A2

32

1

Piece

Packing gland screws

MT184.10.05.002

CuZn39Pb3

33

1

Piece

Brass washer

MT184.10.05.003

CuZn37F30

34

1

Piece

Gland packing

00.2251

Spike

35

1

Piece

Lip seal

ISO 4032-M8

A2-70

36

1

Piece

Lock nut

MT184.10.09.002

CuZn39Pb2

37

1

Piece

Knurled screw

MT184.10.08.003

CuZn39Pb3

38

1

Piece

Cap

MT184.10.08.004

NBR

39

1

Piece

Pump housing

MT184.10.06.001

EN-GJL-200

40

1

Piece

Cylinder cover

MT184.10.06.002

EN-GJL-200

41

1

Piece

Air chamber

MT184.10.06.003

EN-GJL-200

42

1

Piece

Water plug

MT184.10.06.004

CuZn39Pb2

43

1

Piece

Air chamber stud bolt

MT184.10.06.005

9SMn28K

44

1

Piece

Cylinder pipe

MT184.10.06.006

X6CrNi18-10

45

1

Piece

Cap nut

DIN 1587-M12

CuZn39Pb3

46

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

47

1

Piece

Membrane safety valve

SV.01-065.7,5 F3000.4

Spike

48

2

Piece

Straight flange G1“

MT184.10.06.010

EN-GJL-200

49

1

Piece

Poppet valve body

MT184.10.08.001

50

2

Piece

Valve bridge

MT184.10.06.008

X14CrMoS17

51

1

Piece

Cylinder cover seal

MT184.10.06.009

SBR/B-870M

Tab. 4.1

Spare parts list


56

10/2008


MT 184


Item

Quanti ty

Unit

Name


Comments

52

2

Piece

Flat washer

ISO 7089 -8

8-A2

53

2

Piece

Hexagon nut

ISO 4032-M8

8-A2

54

1

Piece

Air chamber seal

MT184.10.06.011

SBR/B-870M

55

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

56

2

Piece

Stud bolt

MT184.10.06.012

X17CrNi16-2

57

2

Piece

Stud bolt

MT184.10.06.013

X17CrNi16-2

58

2

Piece

Seal

DIN 7603-A13x18x1,5

PVC

59

4

Piece

Valve seat seal

MT184.10.06.014

SBR/B-870M

60

3

Piece

Hexagon screw

ISO 4017-M6x16

8.8-A2

61

3

Piece

Hexagon screw

ISO 4017-M8x25

8.8-A2

62

2

Piece

Seal

MT184.10.06.015

SBR/B-870M

63

1

Piece

Plain washer

MT184.10.06.016

X17CrNi16-2

64

1

Piece

Seal

DIN 7603-A13x18x1,5

PVC

65

1

Piece

Seal

DIN 7603-A39x49x2

EPDM

66

1

Piece

Valve seat

MT184.10.07.001

CuZn40Al2

67

1

Piece

Seal in valve seat

MT184.10.07.002

80 NBR 180

68

1

Piece

Delivery side valve pin

MT184.10.01.001

CuZn39Pb3

69

1

Piece

Delivery side valve seat

Mt184.10.01.002

CuZn39Pb3

70

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

71

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

72

1

Piece

Intake side valve pin

MT184.10.02.001

CuZn39Pb3

73

1

Piece

Intake side valve seat

MT184.10.02.002

CuZn39Pb3

74

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

Tab. 4.1

Spare parts list


57

10/2008


MT 184


Item

Quanti ty

Unit

Name


Comments

75

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

76

1

Piece

Hexagon nut

ISO 10511.M6

A2

77

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

78

1

Piece

Rocker shaft

MT184.10.00.001

X14CrMoS17

79

1

Piece

Rocker shaft with thread

MT184.10.00.002

X14CrMoS17

80

4

Piece

Insulating bush

MT184.10.00.003

GP-22

81

1

Piece

Motor clamp rail left

MT184.10.00.004

EN-GJL-200

82

1

Piece

Motor clamp rail right

MT184.10.00.005

EN-GJL-200

83

1

Piece

V-belt pulley

MT184.10.00.006

EN-GJL-200

84

1

Piece

Hexagon screw

ISO 4017-M8x25

8.8

85

5

Piece

Hexagon nut

ISO 4032-M8

8

86

2

Piece

Flat washer

ISO 7089-A-8

140 HV

87

3

Piece

Hexagon screw

ISO 4017-M6x-10

8.8

88

1

Piece

Valve housing complete

MT184.00.06.000

89

1

Piece

Crankcase complete

MT184.00.09.000

90

1

Piece

Intake valve complete

MT184.00.01.000

91

1

Piece

Pressure valve complete

MT184.00.02.000

92

1

Piece

Valve seat

MT184.00.07.000

Tab. 4.1

Spare parts list


58

10/2008

MT 184


5

Assembly and dismantling of the piston pump

5.1

Assembly of the piston pump The piston pump assembly procedure is divided into eight phases: • Assembly phase 1 – Crankshaft (assembly unit 1) • Assembly phase 2 – Connecting rod with piston rod (assembly unit 2) • Assembly phase 3 – Packing gland (assembly unit 3)


• Assembly phase 4 – Intake valve (assembly unit 4) • Assembly phase 5 – Pressure valve (assembly unit 5) • Assembly phase 6 – Gearbox (assembly unit 6) • Assembly phase 7 – Pump housing (assembly unit 7) • Assembly phase 8 – Pump

Tools: • Puller • Punch • Wrench size 10 (2 x), size 13, size 14, size 19 and size 22 • Screwdriver • Vice – not supplied • Soft hammer • Jig 1, 2, 3 and 4

5 Assembly and dismantling of the piston pump

59

10/2008

MT 184


5.1.1


Assembly phase 1 – Crankshaft (assembly unit 1)

3

25

25

Item

Name

3

Crankshaft

24


25


Fig. 5.1

Drawing of the crankshaft (assembly unit 1)

Fig. 5.2

Crankshaft, fully assembled (assembly unit 1)


24

60

10/2008


MT 184


3

Fig. 5.3

25

25 Item

Name

3

Crankshaft

24


25


24

Parts required for assembly


61

10/2008

MT 184


Procedure for assembling the crankshaft (assembly unit 1)

Crankshaft (item 3)


Grooved ball bearing (item 25)



Crankshaft (assembly unit 1)


62

10/2008

MT 184


Assembly procedure for crankshaft (assembly unit 1) • Lightly oil crankshaft (3) to aid assembly of grooved ball bearings. • Fit grooved ball bearing (25) onto crankshaft (3) and position at connecting rod seat.


• Using a soft hammer and jig 2, drive grooved ball bearing (25) onto crankshaft, without bending it, until grooved ball bearing contacts recess.

Fig. 5.4

Assembling the grooved ball bearing with jig 2

• Fit grooved ball bearing (25) onto drive side of crankshaft (3). • Using a soft hammer and jig 2, drive grooved ball bearing (25) onto crankshaft, without bending it, until grooved ball bearing contacts recess.


63

10/2008

MT 184



• Using a soft hammer and jig 3, drive grooved ball bearing (24) onto crankshaft, without bending it, until grooved ball bearing contacts recess.

Fig. 5.5

Assembling the grooved ball bearing with jig 3


64

10/2008

MT 184

5.1.2


Assembly phase 2 – Connecting rod with piston rod (assembly unit 2)


27 29

26

28

1

30, 31

Item

Name

Item

Name

1

Connecting rod

29

Hexagon nut

26

Crosshead

30

Hexagon screw

27

Piston Rod

31

Hexagon nut

28

Straight pin

Fig. 5.6

Drawing of connecting rod with piston rod (assembly unit 2)

Fig. 5.7

Connecting rod with piston rod, fully assembled (assembly unit 2)


65

10/2008

MT 184



29

26

28

1

31

30

27

Fig. 5.8

Item

Name

Item

Name

1

Connecting rod

29

Hexagon nut

26

Crosshead

30

Hexagon screw

27

Piston Rod

31

Hexagon nut

28

Straight pin



66

10/2008

MT 184


Procedure for assembling the connecting rod with piston rod (assembly unit 2)

Connecting rod (item 1)


Crosshead (item 26)

Straight pin (item 28)

Hexagon nut (item 29)

Piston rod (item 27)

Hexagon screw with hexagon nut (item 30, 31)

Connecting rod with piston rod (assembly unit 2)


67

10/2008

MT 184


Assembly procedure for connecting rod with piston rod (assembly unit 2) • Fit crosshead (26) onto connecting rod (1).


• Using a soft hammer and punch, carefully drive straight pin (28) into hole in crosshead (26) and connecting rod (1).

Fig. 5.9

Assembling the crosshead with connecting rod

• Screw hexagon nut (29) onto thread of piston rod (27). • Screw piston rod with thread side onto which nut was screwed into crosshead. • Tighten hexagon nut against crosshead. • Screw hexagon screw with hexagon nut (30, 31) into end of connecting rod.


68

10/2008

MT 184

5.1.3


Assembly phase 3 – Packing gland (assembly unit 3)


35

34

33

32

Item

Name

2


32

Packing gland screw

33

Brass washer

34

Gland packing

35

Lip seal

2

Fig. 5.10

Drawing of the packing gland (assembly unit 3)

Fig. 5.11

Packing gland, fully assembled (assembly unit 3)


69

10/2008

MT 184



32

33 2, 35

34

Fig. 5.12

Item

Name

2


32

Packing gland screw

33

Brass washer

34

Gland packing

35

Lip seal



70

10/2008

MT 184


Procedure for assembling the packing gland (assembly unit 3)


Packing gland housing with lip seal (item 2, 35)

Brass washer (item 33)

Packing gland packing (item 34)

Packing gland screw (item 32)

Packing gland (assembly unit 3)


71

10/2008

MT 184


Assembly procedure for packing gland (assembly unit 3) NOTICE The lip seal (35) is not suitable for repeated assembly and disassembly, as it would be damaged. It is pre-assembled.


• Insert brass washer (33) into packing gland housing (2). • Push four packing gland packs (34) into packing gland housing (2). The abutment of each must be at a 90° offset.

Fig. 5.13

Inserting the packing gland packs

• Screw packing gland screw (32) into packing gland housing.


72

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MT 184

5.1.4


Assembly phase 4 – Intake valve (assembly unit 4)

Item

Name

72


73


74

Valve rubber plate

75

Hold-down

76

Hexagon nut

72


73

74 75 76 Fig. 5.14

Drawing of the intake valve (assembly unit 4)

Fig. 5.15

Intake valve, fully assembled (assembly unit 4)


73

10/2008

MT 184



76

72, 73

Fig. 5.16

75

74

Item

Name

72


73


74

Valve rubber plate

75

Hold-down

76

Hexagon nut



74

10/2008

MT 184


Procedure for assembling the intake valve (assembly unit 4)


Intake side valve pin with intake side valve seat (item 72, 73)

Valve rubber plate (item 74)

Hold-down (item 75)

Hexagon screw (item 76)

Intake valve (assembly unit 4)


75

10/2008

MT 184


Assembly procedure for intake valve (assembly unit 4)

NOTICE The intake side valve pin (72) is pre-assembled with the intake side valve seat (73).


• Fit valve rubber plate (74) onto intake side valve pin (72) with curved side facing outwards. • Fit hold-down (75) onto valve pin with cylindrical side first.

Fig. 5.17

Assembling the hold-down

• Screw hexagon nut (76) onto valve pin. • Carry out same assembly procedure for second intake valve.


76

10/2008

MT 184

5.1.5


Assembly phase 5 – Pressure valve (assembly unit 5)

Item

Name

68


69


71

70

Valve rubber plate

70

71

Hold-down

68


69

Fig. 5.18

Drawing of the pressure valve (assembly unit 5)

Fig. 5.19

Pressure valve, fully assembled (assembly unit 5)


77

10/2008

MT 184



71

69

Fig. 5.20

68

70 Item

Name

68


69


70

Valve rubber plate

71

Hold-down



78

10/2008

MT 184


Procedure for assembling the pressure valve (assembly unit 5)


Delivery side valve seat (item 69)

Valve rubber plate (item 70)

Hold-down (item 71)

Delivery side valve pin (item 68)

Pressure valve (assembly unit 5)


79

10/2008

MT 184


Assembly procedure for pressure valve (assembly unit 5) • Place valve rubber plate (70) on ridged side of delivery side valve seat (69) with curved side facing outwards. • Fit hold-down (71) with cylindrical side first into valve rubber plate (70).


• Fit delivery side valve pin (68) into holes in hold-down and valve seat. Carefully hammer valve pin into valve seat.

Fig. 5.21

Assembling the delivery side valve pin

• Carry out same assembly procedure for second pressure valve.


80

10/2008

MT 184

5.1.6


Assembly phase 6 – Gearbox (assembly unit 6)

11 4, 23

6


A

19 21, 22

7

5

B

13

9

12

C 10

17

18

14

Fig. 5.22

Drawing of the gearbox (assembly unit 6)


81

10/2008


MT 184


Item

Name

Item

Name

A


11

Bearing cover seal

B


12

Oil stripper

C


13

Oil plug

4, 23

Bearing cover, open, with radial shaft seal

14

Duo-piston

5

Gearbox housing

17

Hexagon nut

6


18

Spring ring

7

Gearbox cover

19

Hexagon screw

9

Oil splash guard

21, 22 Angled oiler with nut and seal

10

Packing gland seal

Fig. 5.23

Parts list for gearbox (assembly unit 6)

Fig. 5.24

Gearbox, fully assembled (assembly unit 6)


82

10/2008

MT 184


5

6 A


19

B

9

21, 22

14 13 17, 18 12

10

C

4, 23

7

11

Item

Name

Item

Name

A


11

Bearing cover seal

B


12

Oil stripper

C


13

Oil plug

4, 23


14

Duo-piston

5

Gearbox housing

17

Hexagon nut

6


18

Spring ring

7

Gearbox cover

19

Hexagon screw

9

Oil splash guard

21, 22 Angled oiler with nut and seal

10

Packing gland seal

Fig. 5.25



83

10/2008

MT 184


Procedure for assembling the gearbox (assembly unit 6)


Gearbox housing (item 5)

Oil splash guard (item 9)

Connecting rod with piston rod (assembly unit 2, item B)

Oil stripper (item 12)

Packing gland seal (item 10)

Packing gland (assembly unit 3, item C)

Crankshaft (assembly unit 1, item A)


84

10/2008

MT 184


Bearing cover seal (item 11)


Bearing cover, closed (item 6)

Hexagon screws (item 19)

Bearing Bearing cover cover seal seal (item (item 11) 11)

Bearing cover, open, with radial shaft seal (item 4, 23)

Hexagon screws Hexagon screws (item (item 19) 19)

Gearbox cover (item 7)


85

10/2008

MT 184


Hexagon nut (item 17)


Duo-piston (item 14)

Spring ring with hexagon nut (item 18, 17)

Angled oiler with seal and nut (item 21, 22)

Oil plug (item 13)

Gearbox (assembly unit 5)


86

10/2008

MT 184


Assembly procedure for gearbox (assembly unit 6) • Fit oil splash guard (9) into gearbox housing (5).


• Fit connecting rod with piston rod (B, assembly unit 2) into gearbox housing (5). Do not yet insert crosshead into guide bush, leaving piston rod protruding out of oil splash guard slightly.

Fig. 5.26

Inserting the connecting rod with piston rod

• Push oil stripper (12) onto piston rod by twisting. • Place packing gland seal (12) on packing gland (C, assembly unit 3). • Slot piston rod through packing gland (C, assembly unit 3) and insert crosshead in guide bush. • Fit crankshaft (A, assembly unit 1) into connecting rod base. Use a screwdriver to spread the connecting rod base so the connecting rod bearing can be easily inserted.


87

10/2008


MT 184


Fig. 5.27

Assembling the crankshaft

• Place bearing cover seal (11) against gearbox housing. • Attach closed bearing cover (6) to gearbox housing by hexagon screws (19). NOTICE The radial shaft seal (23) is not suitable for repeated assembly and disassembly, as it would be damaged. It is pre-assembled with the open bearing cover (4).

• Place bearing cover seal (11) against gearbox housing. • Attach open bearing cover (4) to gearbox housing by hexagon screws (19).


88

10/2008


MT 184


Fig. 5.28

Assembling the open bearing cover

• Tighten screw fitting on connecting rod. • Mount gearbox cover (7) on gearbox housing. • Screw hexagon nut (17) onto piston rod. • Fit duo-piston (14) onto piston rod. • Screw hexagon nut with spring ring (17, 18) against duo-piston (14). • Screw angled oiler with seal and nut (item 21, 22) onto gearbox housing.


89

10/2008


MT 184


Fig. 5.29

Assembling the angled oiler

• Insert oil plug (13).


90

10/2008

MT 184

Assembly phase 7 – Pump housing (assembly unit 7)

51

59

39

59

40 60

B

50, 52, 53 41

43

63 42, 58

45


65

46, 77

A

47

48

62

61

5.1.7


Fig. 5.30

Drawing of the pump housing (assembly unit 7)


91

10/2008


MT 184


Item

Name

Item

Name

D

Assembly unit 4

49, 64 Poppet valve body with seal

E

Assembly unit 4

50

Valve bridge

40

Cylinder cover

51

Cylinder cover seal

41

Air chamber

52 ,53 Hexagon nut with washer

42, 58 Water plug with seal

54

Air chamber seal

43

59

Valve seat seal

45, 63 Cap nut with washer

60

Hexagon screws

46, 77 Drain plug with seal

61

Hexagon screws

47, 65 Membrane safety valve with seal

62

Seal

48



Fig. 5.31

Parts list for gearbox (assembly unit 6)

Fig. 5.32

Pump housing, fully assembled (assembly unit 7)


92

10/2008

MT 184


39 46, 77 41 43 47, 65 D

45, 63


48

49, 64

62

59

61 E 60

54 42, 58

51

52, 53 40 50

Item

Name

Item

Name

D

Intake valve (assembly unit 4)

48


E

Pressure valve (assembly unit 5)

49, 64 Poppet valve body with seal

39

Pump housing

50

Valve bridge

40

Cylinder cover

51

Cylinder cover seal

41

Air chamber

52, 53 Hexagon nut with washer

42, 58 Water plug with seal

54

Air chamber seal

43

59

Valve seat seal

45, 63 Cap nut with washer

60

Hexagon screws

46, 77 Drain plug with seal

61

Hexagon screws

47, 65 Membrane safety valve with seal

62

Seal

Fig. 5.33




93

10/2008

MT 184


Procedure for assembling the pump housing (assembly unit 7)


Pump housing (item 39)

Valve seat seal (item 59)

Intake valve (assembly unit 4, item D)

Pressure valve (assembly unit 5, item E)

Valve bridge (item 50)

Hexagon nut with washer (item 32, 53)

Drain plug with seal (item 46, 77)


94

10/2008

MT 184


Seal (item 62)


Straight flange (item 48)


Cylinder cover seal (item 51)

Cylinder cover (item 40)


Poppet valve body with seal (item 49, 64)


95

10/2008

MT 184


Air chamber stud bolt (item 43)


Air chamber seal (item 54)

Air chamber (item 41)

Cap nut with washer (item 45, 63)

Water plug with seal (item 42, 58)

Membrane safety valve with seal (item 47, 65)

Pump housing (assembly unit 7)


96

10/2008

MT 184


Assembly procedure for pump housing (assembly unit 7) NOTICE The cylinder pipe is pre-assembled in the pump housing.

• Place valve seat seal (59) in pump housing (39).


• Place both intake valves (D, assembly unit 4) on one side in pump housing (39). • Place both pressure valves (E, assembly unit ) on other side in pump housing.

Fig. 5.34

Inserting the intake valves and pressure valves in the pump housing

• Place a valve bridge (50) over each intake valve and pressure valve. • Screw together valve bridges (50) with hexagon screw and washer (52, 53) and already fitted stud bolts. • Screw drain plug with seal (46, 77) into tapped hole.


97

10/2008

MT 184


• Fit seals (62) at intake and pressure fittings. • Screw both straight flanges (48) with hexagon screws (61) to intake and pressure fittings. • Place cylinder cover seal (51) against pump housing.


• Screw cylinder cover (40) with hexagon screws (60) to pump housing.

Fig. 5.35

Assembling the cylinder cover

• Screw poppet valve body with seal (49, 64) into cylinder cover. • Screw air chamber bolt (43) into pump housing. • Push air chamber seal (54) over air chamber bolt and place on housing.


98

10/2008


MT 184


Fig. 5.36

Inserting the air chamber seal

• Fit air chamber (41) onto pump housing. Opening for membrane safety valve must be above intake valves. • Screw cap nut with washer (45, 63) onto air chamber bolt. • Screw water plug with seal (42, 58) into air chamber. • Screw membrane safety valve with seal (47, 65) into air chamber using jig 1. The valve seat is pre-assembled.

Fig. 5.37

Assembling the membrane safety valve


99

10/2008

MT 184

5.1.8


Assembly phase 8 – Pump

81, 82

79

84, 85


83, 87

A

87

78

85, 86 C

15

B

Item

Name

Item

Name

C


79


F


81, 82 Motor clamp rails left and right

G


83

V-belt pulley

15

Disk spring

84

Hexagon screw

78

Rocker shaft


Fig. 5.38

Drawing of the pump (assembly unit 8)


100

10/2008


MT 184


Fig. 5.39

Pump, fully assembled (assembly unit 8)


101

10/2008

MT 184


G F

83, 87


85, 86

81, 82

84, 85

79

87

15

78

Item

Name

Item

F


81, 82 Motor clamp rails left and right

G


83

V-belt pulley

15

Disk spring

84

Hexagon screw

78

Rocker shaft


79


87

Fig. 5.40

Name

Hexagon screw



102

10/2008

MT 184


Procedure for assembling the pump (assembly unit 8)


Gearbox (F, assembly unit 6)

Pump housing (G, assembly unit 7)

Hexagon nut with washer (item 85, 86)

Disk spring (item 15)

V-belt pulley with hexagon screw (item 83, 87)

Rocker shaft (item 78)

Motor clamp rails left and right (item 81, 82)


103

10/2008

MT 184


Hexagon screw (item 87)


Rocker shaft with thread (item 79)

Hexagon screw with hexagon nut (item 84, 85)

Piston pump


104

10/2008

MT 184


Assembly procedure for pump (assembly unit 8) • Grease piston and insert carefully into cylinder pipe. Then place pump housing (G, assembly unit 7) against Gearbox (F, assembly unit 6). Screw together pump housing and gearbox with hexagon nut (85) and preassembled stud bolts.


• Fit packing gland (C, assembly unit 3) with hexagon nut and washer (85, 86) on stud bolts.

Fig. 5.41

Fitted packing gland

• Place disk spring (15) with round side facing downwards into groove in crankshaft. • Push V-belt pulley (83) with loosely fitted hexagon screw (87) over disk spring onto crankshaft and then tighten hexagon screw. • Fit rocker shaft (78) into hole on gearbox housing.


105

10/2008


MT 184


Fig. 5.42

Gearbox housing with rocker shafts and V-belt pulley

• Slot left and right motor clamp rails (81, 82) with pre-assembled hexagon screw side onto rocker shaft. The insulating bushes are pre-assembled in the motor clamp rails. • Fix rocker shaft with hexagon screw (87) on gearbox housing. • Route rocker shaft with thread (79) into rear holes on motor clamp rails.

Fig. 5.43

Assembling the rocker shaft

• Screw hexagon screw (84) into tapped hole of rocker shaft with thread (79) and lock with hexagon nut (85).


106

10/2008

MT 184


5.2

Dismantling the piston pump

5.2.1

Dismantling assembly phase 8 – Pump • Loosen hexagon nut (85) and unscrew hexagon screw (84) from tapped hole of rocker shaft with thread (79).


• Pull rocker shaft with thread (79) out of rear holes on motor clamp rails.

Fig. 5.44

Dismantling the rocker shaft

• Detach left and right motor clamp rails (81, 82) from rocker shaft. The insulating bushes remain fitted in the motor clamp rails. • Unscrew hexagon screw (87) from gearbox housing • Pull rocker shaft (78) out of hole in gearbox housing. • Loosen hexagon screw (87) and detach V-belt pulley (83) from crankshaft over disk spring.


107

10/2008


MT 184


Fig. 5.45

Dismantling the V-belt pulley

• Lever disk spring (15) out of groove on crankshaft with screwdriver. • Unscrew hexagon nut and washer (85, 86) from stud bolts and detach packing gland (C, assembly unit 3) from pump. • Unscrew hexagon nut (85) from stud bolts and detach pump housing (G, assembly unit 7) from gearbox (F, assembly unit 6). Carefully guide piston out of cylinder pipe when doing so.

Fig. 5.46

Dismantling the pump housing


108

10/2008


MT 184


Fig. 5.47

Piston pumps, dismantled into assembly units


109

10/2008

MT 184

5.2.2


Dismantling assembly phase 7 – Pump housing • Unscrew membrane safety valve (47) from air chamber (41) using jig 1. Remove seal (65).


NOTICE The valve seat of the membrane safety valve remains fitted.

• Unscrew water plug with seal (42, 58) from air chamber (41). • Unscrew cap nut with washer (45, 63) from air chamber bolt (43). • Lift air chamber (41) from pump housing (39).

Fig. 5.48

Removing the air chamber

• Pull air chamber seal (54) over air chamber bolt (43) and remove from housing. • Unscrew air chamber bolt from pump housing (39). • Unscrew poppet valve body with seal (49, 64) from cylinder cover (40).


110

10/2008


MT 184


Fig. 5.49

Dismantling the poppet valve body

• Loosen hexagon screws (60) and take cylinder cover (40) with cylinder cover seal (51) from pump housing. • Loosen hexagon screws (61) and remove both straight flanges (48) with seals (62) from intake and pressure fittings. • Unscrew drain plug with seal (46, 77) from tapped hole in pump housing. • Unscrew hexagon screws and washers (52, 53) from stud bolts on valve bridges (50). • Lift valve bridges (50) from intake and pressure valves.

Fig. 5.50

Removing the intake and pressure valves


111

10/2008

MT 184


• Take pressure valve (E, assembly unit 5) out of pump housing. • Take intake valve (D, assembly unit 4) out of pump housing. • Remove valve seat seal (59) from pump housing.


NOTICE The cylinder pipe remains fitted in the pump housing.

Fig. 5.51

Pump housing, dismantled


112

10/2008

MT 184

5.2.3


Dismantling assembly phase 6 – Gearbox • Remove oil plug (13). • Unscrew angled oiler with seal and nut (item 21, 22) from gearbox housing (5). • Unscrew hexagon nut with spring ring (17, 18) from duo-piston (14).


• Pull duo-piston (14) from piston rod (27).

Fig. 5.52

Detaching the duo-piston

• Unscrew hexagon nut (17) from piston rod (27). • Lever gearbox cover (7) from gearbox housing (5). • Unscrew hexagon screws (19) from gearbox housing and remove open bearing cover (4) with bearing cover seal (11) from gearbox housing. NOTICE The radial shaft seal (23) is not suitable for repeated assembly and disassembly, as it would be damaged. It remains fitted in the open bearing cover (4).

• Unscrew hexagon screws (19) from gearbox housing and remove closed bearing cover (6) with bearing cover seal (11) from gearbox housing.


113

10/2008

MT 184



• Loosen screw fitting on connecting rod.

Fig. 5.53

Loosening the connecting rod screw fitting

• Pull crankshaft (A, assembly unit 1) out of connecting rod base. Use a screwdriver to spread the connecting rod base so the connecting rod bearing can be easily removed. • Pull piston rod out of packing gland (C, assembly unit 3) and crosshead out of guide bush. Leave connecting rod in gearbox housing.

Fig. 5.54

Removing the packing gland


114

10/2008

MT 184


• Take packing gland seal (12) from packing gland (C, assembly unit 3). • Pull oil stripper (12) from piston rod by twisting. • Take connecting rod with piston rod (B, assembly unit 2) out of gearbox housing (5).


• Lever oil splash guard (9) from gearbox housing (5).

Fig. 5.55

Gearbox, dismantled


115

10/2008

MT 184

5.2.4


Dismantling assembly phase 5 – Pressure valve


• Carefully hammer delivery side valve pin (68) out of delivery side valve seat (69).

Fig. 5.56

Driving valve pin out of valve seat

• Pull valve pin out of hole in hold-down (71) and valve seat. • Pull hold-down (71) out of valve rubber plate (70). • Take valve rubber plate (70) from valve seat. • Carry out same dismantling procedure for second pressure valve.

Fig. 5.57

Pressure valve, disassembled


116

10/2008

MT 184

5.2.5


Dismantling assembly phase 4 – Intake valve • Unscrew hexagon nut (76) from intake side valve pin (72). • Pull hold-down (75) from intake side valve pin (73).


• Take valve rubber plate (74) from intake side valve pin (72).

Fig. 5.58

Removing the valve rubber plate

• Intake side valve pin (72) remains assembled with intake side valve seat (73). • Carry out same dismantling procedure for second intake valve.

Fig. 5.59

Pressure valve, disassembled


117

10/2008

MT 184

5.2.6


Dismantling assembly phase 3 – Packing gland • Unscrew packing gland screw (32) from packing gland housing (2).


• Drive packing gland packs (34) out of packing gland housing (2). Strike the brass washer (33) with a punch to do so.

Fig. 5.60

Driving out the packing gland packs

• Take brass washer (33) out of packing gland housing. NOTICE The lip seal (35) is not suitable for repeated assembly and disassembly, as it would be damaged. It remains fitted.

Fig. 5.61

Packing gland, disassembled


118

10/2008

MT 184

5.2.7


Dismantling assembly phase 2 – Connecting rod with piston rod • Unscrew hexagon screw with hexagon nut (30, 31) from end of connecting rod. • Loosen hexagon nut (29) of crosshead and unscrew piston rod (27) from crosshead (26). • Unscrew hexagon nut (29) from thread of piston rod (27).


• Using a soft hammer and punch, carefully drive straight pin (28) out of hole in crosshead (26) and connecting rod (1).

Fig. 5.62

Driving out the straight pin

• Take crosshead (26) from connecting rod (1).

Fig. 5.63

Connecting rod, dismantled


119

10/2008

MT 184

5.2.8


Dismantling assembly phase 1 – Crankshaft • Place puller over grooved ball bearing (24). Press hook arms evenly onto grooved ball bearing. Turn adjuster thread against shaft end. Ensure jig is centred.


Detach grooved ball bearing from crankshaft (3) by carefully turning adjuster thread.

Fig. 5.64

Pulling off the grooved ball bearing

• Pull grooved ball bearing (25) from crankshaft in same way using a puller. • Place grooved ball bearing (25) with crankshaft on jig 4. Drive the grooved ball bearing from the shaft by carefully hammering on the shaft. Use jig 4 and an additional vice as braces.


120

10/2008


MT 184


Fig. 5.65

Driving out the grooved ball bearing

Fig. 5.66

Crankshaft, dismantled


121

10/2008

MT 184


6

6 Tasks


Tasks

Tasks / Exercises

Topic

Worksheet 1

Introduction to the piston pump

Worksheet 2

Design, function and applications

Worksheet 3

Identifying causes of faults

Worksheet 4

Sealing systems

Worksheet 5

Inspection

Worksheet 6

Servicing

Worksheet 7

Repairs

Worksheet 8

Wearing parts

Worksheet 9

Assembly of the piston pump

Worksheet 10

Piston replacement

Worksheet 11

Parts identification using the spare parts drawing

Worksheet 12

Spare parts ordering

122

10/2008

MT 184

Spare parts drawing and spare parts list

83, 87

81, 82

79, 80

84, 85

87

79, 80

85, 86


8

6.1


Fig. 6.1

6 Tasks


123

10/2008

MT 184


11 19

4, 23

6 3 - 15

22


21

16

7 1 30,31 24 25 5 26 28 13

29

9

27 12

32 2 33 18 17

35 34

14

10 20 8

Fig. 6.2

6 Tasks


124

57

42 58

Fig. 6.3

6 Tasks 44

60

36

64

51 38 49 37

40

43

59

70

71

54 68

39

50, 52, 53

41

69

58 66

67 47

73 74

72

62

48

47

75 46, 77 76

65

61

MT 184

63

45


10/2008



125

10/2008


MT 184


Item

Quanti ty

Unit

Name


1

1

Piece

Connecting rod

MT184.10.04.001

2

1

Piece


MT184.10.05.002

3

1

Piece

Crankshaft

MT184.10.03.001

4

1

Piece

Bearing cover, open

MT184.10.10.001

5

1

Piece

Gearbox housing

MT184.10.09.001

EN-GJL-200

6

1

Piece


MT184.10.09.002

EN-GJL-200

7

1

Piece

Gearbox cover

MT184.10.09.003

DOC04

8

1

Piece

Base plate

MT184.10.09.004

S235JR

9

1

Piece

Oil splash guard

MT184.10.09.005

DOC04

10

1

Piece

Packing gland seal

MT184.10.09.006

SBR/B-870M

11

2

Piece

Bearing cover seal

MT184.10.09.007

SBR/B-870M

12

1

Piece

Oil stripper

MT184.10.09.008

60NBR693 SW

13

1

Piece

Oil plug

MT184.10.09.009

CuZn39Pb3

14

1

Piece

Duo-piston

PM10

Simirit

15

1

Piece

Disk spring

DIN 6888-5x7,5

16

8

Piece

Hexagon nut

ISO 4032-M6

8

17

2

Piece

Hexagon nut

ISO 4032-M8

8

18

1

Piece

Spring ring

DIN 127-A-8

A2

19

6

Piece

Hexagon screw

ISO 4017-M6x12

8.8

20

4

Piece

Rubber buffer

500029

GMT

21

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

22

2

Piece


G1/8

Spike

23

1

Piece

Radial shaft seal

DIN 3760-A16x35x7

NBR

24

2

Piece


DIN 625-6202

25

1

Piece


DIN 625-6203

Tab. 6.1

6 Tasks

Comments

Spare parts list

126

10/2008


MT 184


Item

Quanti ty

Unit

Name


Comments

26

1

Piece

Crosshead

MT184.10.04.002

EN-GJL-200

27

1

Piece

Piston Rod

MT184.10.04.003

X14CrMoS17

28

1

Piece

Straight pin

ISO 8734-12x35

C1

29

1

Piece

Hexagon nut

ISO 4032-M8

8-A2

30

1

Piece

Hexagon screw

ISO 4017-M6x25

8.8

31

1

Piece

Hexagon nut

ISO 4032-M6

8-A2

32

1

Piece


MT184.10.05.002

CuZn39Pb3

33

1

Piece

Brass washer

MT184.10.05.003

CuZn37F30

34

1

Piece

Gland packing

00.2251

Spike

35

1

Piece

Lip seal

ISO 4032-M8

A2-70

36

1

Piece

Lock nut

MT184.10.09.002

CuZn39Pb2

37

1

Piece

Knurled screw

MT184.10.08.003

CuZn39Pb3

38

1

Piece

Cap

MT184.10.08.004

NBR

39

1

Piece

Pump housing

MT184.10.06.001

EN-GJL-200

40

1

Piece

Cylinder cover

MT184.10.06.002

EN-GJL-200

41

1

Piece

Air chamber

MT184.10.06.003

EN-GJL-200

42

1

Piece

Water plug

MT184.10.06.004

CuZn39Pb2

43

1

Piece


MT184.10.06.005

9SMn28K

44

1

Piece

Cylinder pipe

MT184.10.06.006

X6CrNi18-10

45

1

Piece

Cap nut

DIN 1587-M12

CuZn39Pb3

46

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

47

1

Piece


SV.01-065.7,5 F3000.4

Spike

48

2

Piece


MT184.10.06.010

EN-GJL-200

49

1

Piece

Poppet valve body

MT184.10.08.001

50

2

Piece

Valve bridge

MT184.10.06.008

X14CrMoS17

51

1

Piece

Cylinder cover seal

MT184.10.06.009

SBR/B-870M

Tab. 6.1

6 Tasks

Spare parts list

127

10/2008


MT 184


Item

Quanti ty

Unit

Name


Comments

52

2

Piece

Flat washer

ISO 7089 -8

8-A2

53

2

Piece

Hexagon nut

ISO 4032-M8

8-A2

54

1

Piece

Air chamber seal

MT184.10.06.011

SBR/B-870M

55

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

56

2

Piece

Stud bolt

MT184.10.06.012

X17CrNi16-2

57

2

Piece

Stud bolt

MT184.10.06.013

X17CrNi16-2

58

2

Piece

Seal

DIN 7603-A13x18x1,5

PVC

59

4

Piece

Valve seat seal

MT184.10.06.014

SBR/B-870M

60

3

Piece

Hexagon screw

ISO 4017-M6x16

8.8-A2

61

3

Piece

Hexagon screw

ISO 4017-M8x25

8.8-A2

62

2

Piece

Seal

MT184.10.06.015

SBR/B-870M

63

1

Piece

Plain washer

MT184.10.06.016

X17CrNi16-2

64

1

Piece

Seal

DIN 7603-A13x18x1,5

PVC

65

1

Piece

Seal

DIN 7603-A39x49x2

EPDM

66

1

Piece

Valve seat

MT184.10.07.001

CuZn40Al2

67

1

Piece

Seal in valve seat

MT184.10.07.002

80 NBR 180

68

1

Piece


MT184.10.01.001

CuZn39Pb3

69

1

Piece


Mt184.10.01.002

CuZn39Pb3

70

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

71

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

72

1

Piece


MT184.10.02.001

CuZn39Pb3

73

1

Piece


MT184.10.02.002

CuZn39Pb3

74

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

Tab. 6.1

6 Tasks

Spare parts list

128

10/2008


MT 184


Item

Quanti ty

Unit

Name


Comments

75

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

76

1

Piece

Hexagon nut

ISO 10511.M6

A2

77

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

78

1

Piece

Rocker shaft

MT184.10.00.001

X14CrMoS17

79

1

Piece


MT184.10.00.002

X14CrMoS17

80

4

Piece

Insulating bush

MT184.10.00.003

GP-22

81

1

Piece


MT184.10.00.004

EN-GJL-200

82

1

Piece


MT184.10.00.005

EN-GJL-200

83

1

Piece

V-belt pulley

MT184.10.00.006

EN-GJL-200

84

1

Piece

Hexagon screw

ISO 4017-M8x25

8.8

85

5

Piece

Hexagon nut

ISO 4032-M8

8

86

2

Piece

Flat washer

ISO 7089-A-8

140 HV

87

3

Piece

Hexagon screw

ISO 4017-M6x-10

8.8

88

1

Piece


MT184.00.06.000

89

1

Piece

Crankcase complete

MT184.00.09.000

90

1

Piece


MT184.00.01.000

91

1

Piece


MT184.00.02.000

92

1

Piece

Valve seat

MT184.00.07.000

Tab. 6.1

6 Tasks

Spare parts list

129

10/2008

MT 184

6.2


Worksheet 1: Introduction to the piston pump, page 1 Objective: To obtain an overview of the design and function of the piston pump.

Exercise:


You are provided with an assembled pump. Dismantle the pump so that all the component parts are laid out before you.

6 Tasks

130

10/2008

MT 184


Worksheet 1, page 2


Pick up the pump drawings and the parts list. Locate the components in the drawings. Refer to the parts list to find out the correct names of the components.

6 Tasks

131

10/2008

MT 184


Worksheet 1, page 3 You are now familiar enough with the overall design of the pump to be able to answer the following questions: 1. With what type of displacement device is the pump fitted?


2. Does a piston pump have a specific direction of rotation? Or are clockwise and anti-clockwise both possible?

3. Can you explain the basic operating principle of a piston pump?

4. Look at the materials in the parts list. For which media could the pump be suitable?

6 Tasks

132

10/2008

MT 184

6.3


Worksheet 2: Design, function and applications of the piston pump, page 1 Objective: To explain the design of the pump. To understand and describe its method of operation and usage. Exercise: 1. Describe the design of the pump.


Use the drawings.

2. Name the five key components.

6 Tasks

133

10/2008

MT 184


Worksheet 2, page 2


3. Explain the method of operation of the pump. Explain the delivery principle.

4. In what areas is the piston pump used?

6 Tasks

134

10/2008

MT 184

6.4


Worksheet 3: Identifying causes of faults, page 1 Objective: To identify or suspect likely causes of faults in response to specific malfunctions while the pump is operating. Exercise: Try to find the causes of the faults listed in the table below. Note down your assumptions in the right-hand section of the table. You can exclude systemrelated disturbances.


Fault

Suspected cause

Medium leaking from pump body

Running noise has markedly increased

The pressure difference usually generated between the inlet and outlet is no longer being attained The pressure difference is much less than normal The pump housing has a much higher surface temperature than normal

The current consumption of the drive motor has increased significantly compared to normal operating conditions Service life of piston too short

6 Tasks

135

10/2008

MT 184

6.5


Worksheet 4: Sealing systems, page 1 Objective: To divide sealing systems into basic categories and identify them based on the example of the pistons. Information: Sealing systems we can find in pumps are classified as follows:


Sealing systems

6 Tasks

Static seals

Dynamic seals

(seals subject to stationary stress)

(seals subject to motion)

136

10/2008

MT 184


Worksheet 4, page 2 Exercise: 1. Here you see the sectional drawing of the pump. • In the sectional drawing, mark the static seals as S and the dynamic seals as D.


• What functions do the static and dynamic seals perform?

6 Tasks

137

10/2008

MT 184


Worksheet 4, page 3 When you have identified the sealing systems used in the piston pump, move on to the following exercise.


2. Describe the design and method of operation of a shaft seal based on the floating ring principle.

3. Look at a shaft seal based on the packing gland principle and describe it.

6 Tasks

138

10/2008

MT 184

6.6


Worksheet 5: Inspection of pumps, page 1 Objective: To know what the term “inspection” involves, and to draw up an inspection plan.

Exercise:


1. What does the term “inspection” mean in the context of technical maintenance? Mark the statements you consider to be true or false in the Yes or No column of the following table as appropriate.

Activity

Yes

No

The current actual status of a pump is recorded and assessed Components such as pistons or seals are replaced as a preventive maintenance measure Shaft bearings are lubricated and couplings re-aligned Entire pump units are replaced An inspection is always carried out with the system stopped During an inspection operating data of the pump system are measured (read) and entered in an inspection plan An inspection can be seen as equivalent to preventive repair Inspection is a routine operation in machinery and plant maintenance

6 Tasks

139

10/2008

MT 184


Worksheet 5, page 2 When you have established what the term “inspection” means, move on to the following exercise. 2. Imagine we were talking about a vital piston pump in a domestic water process. Let’s also assume that this pump is similar in design to the pump from our MT 184 practice kit.


Draw up an inspection plan by mean of which an inspection can be documented.

Inspection plan Pump:

Inspected by:

Serial no.:

Date:

Item

6 Tasks

Comments

140

10/2008

MT 184

6.7


Worksheet 6: Servicing of pumps, page 1 Objective: To know what is meant by the term “servicing”. Exercise: 1. What does the term “servicing” mean in the context of technical maintenance?


Mark the statements you consider to be true or false in the Yes or No column of the following table as appropriate.

Activity

Yes

No

Components such as pistons, rod seals and gaskets are replaced as a preventive maintenance measure The object of servicing is to record and assess the current actual status of a pump Servicing of a pump is a routine operation, carried out at predetermined intervals A service is usually carried out with the system stopped Servicing can be seen as equivalent to preventive repair During a service, packing glands are repositioned, couplings adjusted or oil fillings changed for example Entire pump units are replaced Servicing is always carried out when damage to a pump is identified

6 Tasks

141

10/2008

MT 184


Worksheet 6, page 2 When you have established what the term “servicing” means, move on to the following exercise. 2. Do you think that routine servicing is useful and necessary for the piston pump from our MT 184 practice kit?


Give reasons for your decision.

3. Let’s assume that two piston pumps with the classic differing shaft seals are being used in a domestic water process. What servicing operations need to be carried out on the packing gland type shaft seal and on the floating ring seal type?

6 Tasks

142

10/2008

MT 184

6.8


Worksheet 7: Repairs to pumps, page 1 Objective: To know what is meant by the term “repairs” in this context and to draw up a preventive maintenance plan.

Exercise:


1. What does the term “repairs” mean in the context of technical maintenance? Mark the statements you consider to be true or false in the Yes or No column of the following table as appropriate.

Activity

Yes

No

Repairs involve replacing well-used parts with new ones, for example pistons and seals Repairs are carried out when damage has occurred to the pump Repairs may also be carried out as routine and preventive maintenance measures to prevent damage and stoppages from occurring in the first place Entire pump units are replaced Preventive maintenance can prevent a pump from failing Repairs are normally carried out with the system stopped If servicing is carried out on a regular basis, repairs are not needed

6 Tasks

143

10/2008

MT 184


Worksheet 7, page 2 When you have established what the term “repairs” means, move on to the following exercise. 2. Let us assume that our piston pump represents an important assembly in a domestic water process. A failure of the pump would result in the entire line being shut down. In view of this, the pump is inspected and serviced at regular intervals.


To achieve the most reliable operation possible, the plant management decides to carry out routine preventive repairs to the unit. Draw up a repair order for carrying out and documenting the work. Use the drawings. Inspection order Pump:

Inspected by:

Serial no.:

Date:

Procedure

Comments/Status

Parts to be replaced:

Parts to be checked:

6 Tasks

144

10/2008

MT 184

6.9


Worksheet 8: Wearing parts on the piston pump, page 1 Objective: To identify the wearing parts on the piston pump. Exercise:


1. Mark the wearing parts on the pump drawing and name them by way of example.

6 Tasks

145

10/2008

MT 184


Worksheet 8, page 2

2. Of what material are the wearing parts of the piston pump made? Enter the wearing parts from the previous page in the table with their material data or standard designations.

Material


Wearing part

6 Tasks

146

10/2008

MT 184

6.10


Worksheet 9: Assembling the piston pump, page 1 Objective: To structure the assembly process. To identify which assembly units and phases can be compiled. Exercise: You have laid out all the component parts of the piston pump in front of you. Your task is to assemble the pump.


To do this, first assembly individual assembly units. Then combine the assembly units to create the overall system in a sequence of assembly phases. 1. Collect the components from which you can compile assembly units and phases. Name the assembly units and phases. Use the drawings.

• Item

6 Tasks

Name

147

10/2008

MT 184


Worksheet 9, page 2


• Item

Name

Item

Name

Item

Name

•

•

6 Tasks

148

10/2008

MT 184


Worksheet 9, page 3


• Item

Name

Item

Name

•

6 Tasks

149

10/2008

MT 184


Worksheet 9, page 4

• Name


Item

6 Tasks

150

10/2008

MT 184


Worksheet 9, page 5

2. When you have put together the various assembly units, the next step is to assemble the pump. You should carry out this phase and represent it in a structure corresponding to the pattern shown.


Set out the identified assembly phases through to the complete pump.

Gearing

Parts x, y, ...

Parts x, y, ...

Piston pump

6 Tasks

151

10/2008

MT 184


Worksheet 9, page 6 Procedure for assembling the piston pump



Piston pump

6 Tasks

152

10/2008

MT 184

6.11


Worksheet 10: Piston replacement, page 1 Objective: Planning and execution of piston replacement on a piston pump. Exercise: 1. Your task is to replace the piston on a piston pump.


Set out your method in the pre-compiled work plan. Use the drawings.

6 Tasks

153

10/2008

MT 184


Worksheet 10, page 2

Work plan Name: Piston pump – Piston replacement Date:

Carried out by:

Order no.:

Date:

Proced ure

Procedure

Tools


Dismantling

Assembly

Estimated time required: ____ min

6 Tasks

154

10/2008

MT 184

6.12


Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1 Objective: To assign items from a spare parts list to a spare parts drawing. Exercise: You are given a spare parts drawing on which the item numbers have not yet been entered. Refer to the supplied spare parts list.


Enter the item numbers from the 1st column of the spare parts list in the fields in the spare parts drawing.

6 Tasks

155

10/2008

MT 184




Fig. 6.4

6 Tasks


156

10/2008

MT 184




Fig. 6.5

6 Tasks


157

10/2008

MT 184




Fig. 6.6

6 Tasks


158

10/2008

MT 184



Worksheet 11, page 5 Item

Quanti ty

Unit

Name


1

1

Piece

Connecting rod

MT184.10.04.001

2

1

Piece


MT184.10.05.002

3

1

Piece

Crankshaft

MT184.10.03.001

4

1

Piece

Bearing cover, open

MT184.10.10.001

5

1

Piece

Gearbox housing

MT184.10.09.001

EN-GJL-200

6

1

Piece


MT184.10.09.002

EN-GJL-200

7

1

Piece

Gearbox cover

MT184.10.09.003

DOC04

8

1

Piece

Base plate

MT184.10.09.004

S235JR

9

1

Piece

Oil splash guard

MT184.10.09.005

DOC04

10

1

Piece

Packing gland seal

MT184.10.09.006

SBR/B-870M

11

2

Piece

Bearing cover seal

MT184.10.09.007

SBR/B-870M

12

1

Piece

Oil stripper

MT184.10.09.008

60NBR693 SW

13

1

Piece

Oil plug

MT184.10.09.009

CuZn39Pb3

14

1

Piece

Duo-piston

PM10

Simirit

15

1

Piece

Disk spring

DIN 6888-5x7,5

16

8

Piece

Hexagon nut

ISO 4032-M6

8

17

2

Piece

Hexagon nut

ISO 4032-M8

8

18

1

Piece

Spring ring

DIN 127-A-8

A2

19

6

Piece

Hexagon screw

ISO 4017-M6x12

8.8

20

4

Piece

Rubber buffer

500029

GMT

21

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

22

2

Piece


G1/8

Spike

23

1

Piece

Radial shaft seal

DIN 3760-A16x35x7

NBR

24

2

Piece


DIN 625-6202

25

1

Piece


DIN 625-6203

Tab. 6.2

6 Tasks

Comments

Spare parts list

159

10/2008

MT 184




Quanti ty

Unit

Name


Comments

26

1

Piece

Crosshead

MT184.10.04.002

EN-GJL-200

27

1

Piece

Piston Rod

MT184.10.04.003

X14CrMoS17

28

1

Piece

Straight pin

ISO 8734-12x35

C1

29

1

Piece

Hexagon nut

ISO 4032-M8

8-A2

30

1

Piece

Hexagon screw

ISO 4017-M6x25

8.8

31

1

Piece

Hexagon nut

ISO 4032-M6

8-A2

32

1

Piece


MT184.10.05.002

CuZn39Pb3

33

1

Piece

Brass washer

MT184.10.05.003

CuZn37F30

34

1

Piece

Gland packing

00.2251

Spike

35

1

Piece

Lip seal

ISO 4032-M8

A2-70

36

1

Piece

Lock nut

MT184.10.09.002

CuZn39Pb2

37

1

Piece

Knurled screw

MT184.10.08.003

CuZn39Pb3

38

1

Piece

Cap

MT184.10.08.004

NBR

39

1

Piece

Pump housing

MT184.10.06.001

EN-GJL-200

40

1

Piece

Cylinder cover

MT184.10.06.002

EN-GJL-200

41

1

Piece

Air chamber

MT184.10.06.003

EN-GJL-200

42

1

Piece

Water plug

MT184.10.06.004

CuZn39Pb2

43

1

Piece


MT184.10.06.005

9SMn28K

44

1

Piece

Cylinder pipe

MT184.10.06.006

X6CrNi18-10

45

1

Piece

Cap nut

DIN 1587-M12

CuZn39Pb3

46

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

47

1

Piece


SV.01-065.7,5 F3000.4

Spike

48

2

Piece


MT184.10.06.010

EN-GJL-200

49

1

Piece

Poppet valve body

MT184.10.08.001

50

2

Piece

Valve bridge

MT184.10.06.008

Tab. 6.3

6 Tasks

X14CrMoS17

Spare parts list

160

10/2008

MT 184




Quanti ty

Unit

Name


Comments

51

1

Piece

Cylinder cover seal

MT184.10.06.009

SBR/B-870M

52

2

Piece

Flat washer

ISO 7089 -8

8-A2

53

2

Piece

Hexagon nut

ISO 4032-M8

8-A2

54

1

Piece

Air chamber seal

MT184.10.06.011

SBR/B-870M

55

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

56

2

Piece

Stud bolt

MT184.10.06.012

X17CrNi16-2

57

2

Piece

Stud bolt

MT184.10.06.013

X17CrNi16-2

58

2

Piece

Seal

DIN 7603-A13x18x1,5

PVC

59

4

Piece

Valve seat seal

MT184.10.06.014

SBR/B-870M

60

3

Piece

Hexagon screw

ISO 4017-M6x16

8.8-A2

61

3

Piece

Hexagon screw

ISO 4017-M8x25

8.8-A2

62

2

Piece

Seal

MT184.10.06.015

SBR/B-870M

63

1

Piece

Plain washer

MT184.10.06.016

X17CrNi16-2

64

1

Piece

Seal

DIN 7603-A13x18x1,5

PVC

65

1

Piece

Seal

DIN 7603-A39x49x2

EPDM

66

1

Piece

Valve seat

MT184.10.07.001

CuZn40Al2

67

1

Piece

Seal in valve seat

MT184.10.07.002

80 NBR 180

68

1

Piece


MT184.10.01.001

CuZn39Pb3

69

1

Piece


Mt184.10.01.002

CuZn39Pb3

70

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

71

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

72

1

Piece


MT184.10.02.001

CuZn39Pb3

73

1

Piece


MT184.10.02.002

CuZn39Pb3

Tab. 6.4

6 Tasks

Spare parts list

161

10/2008

MT 184




Quanti ty

Unit

Name


Comments

74

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

75

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

76

1

Piece

Hexagon nut

ISO 10511.M6

A2

77

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

78

1

Piece

Rocker shaft

MT184.10.00.001

X14CrMoS17

79

1

Piece


MT184.10.00.002

X14CrMoS17

80

4

Piece

Insulating bush

MT184.10.00.003

GP-22

81

1

Piece


MT184.10.00.004

EN-GJL-200

82

1

Piece


MT184.10.00.005

EN-GJL-200

83

1

Piece

V-belt pulley

MT184.10.00.006

EN-GJL-200

84

1

Piece

Hexagon screw

ISO 4017-M8x25

8.8

85

5

Piece

Hexagon nut

ISO 4032-M8

8

86

2

Piece

Flat washer

ISO 7089-A-8

140 HV

87

3

Piece

Hexagon screw

ISO 4017-M6x-10

8.8

88

1

Piece


MT184.00.06.000

89

1

Piece

Crankcase complete

MT184.00.09.000

90

1

Piece


MT184.00.01.000

91

1

Piece


MT184.00.02.000

92

1

Piece

Valve seat

MT184.00.07.000

Tab. 6.5

6 Tasks

Spare parts list

162

10/2008

MT 184

6.13


Worksheet 12: Spare parts ordering, page 1 Objective: To place a technically unambiguous spare parts order.

Exercise: You are going to carry out a repair, and need replacement parts for your piston pump. All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 10/2008

Select three parts and make a spare parts order. Use the documents provided.

Spare parts order for pump:

Parts:

6 Tasks

163

10/2008

MT 184


7

7 Solutions


Solutions

Tasks / Exercises

Topic

Worksheet 1

Introduction to the piston pump

Worksheet 2

Design, function and applications

Worksheet 3

Identifying causes of faults

Worksheet 4

Sealing systems

Worksheet 5

Inspection

Worksheet 6

Servicing

Worksheet 7

Repairs

Worksheet 8

Wearing parts

Worksheet 9

Assembly of the piston pump

Worksheet 10

Piston replacement

Worksheet 11

Parts identification using the spare parts drawing

Worksheet 12

Spare parts ordering

164

10/2008

MT 184

Spare parts drawing and spare parts list

83, 87

81, 82

79, 80

84, 85

87

79, 80

85, 86


8

7.1


Fig. 7.1

7 Solutions


165

10/2008

MT 184


11 19

4, 23

6 3 - 15

22


21

16

7 1 30,31 24 25 5 26 28 13

29

9

27 12

32 2 33 18 17

35 34

14

10 20 8

Fig. 7.2

7 Solutions


166

57

42 58

Fig. 7.3

7 Solutions 44

60

36

64

51 38 49 37

40

43

59

70

71

54 68

39

50, 52, 53

41

69

58 66

67 47

73 74

72

62

48

47

75 46, 77 76

65

61

MT 184

63

45


10/2008



167

10/2008


MT 184


Item

Quanti ty

Unit

Name


1

1

Piece

Connecting rod

MT184.10.04.001

2

1

Piece


MT184.10.05.002

3

1

Piece

Crankshaft

MT184.10.03.001

4

1

Piece

Bearing cover, open

MT184.10.10.001

5

1

Piece

Gearbox housing

MT184.10.09.001

EN-GJL-200

6

1

Piece


MT184.10.09.002

EN-GJL-200

7

1

Piece

Gearbox cover

MT184.10.09.003

DOC04

8

1

Piece

Base plate

MT184.10.09.004

S235JR

9

1

Piece

Oil splash guard

MT184.10.09.005

DOC04

10

1

Piece

Packing gland seal

MT184.10.09.006

SBR/B-870M

11

2

Piece

Bearing cover seal

MT184.10.09.007

SBR/B-870M

12

1

Piece

Oil stripper

MT184.10.09.008

60NBR693 SW

13

1

Piece

Oil plug

MT184.10.09.009

CuZn39Pb3

14

1

Piece

Duo-piston

PM10

Simirit

15

1

Piece

Disk spring

DIN 6888-5x7,5

16

8

Piece

Hexagon nut

ISO 4032-M6

8

17

2

Piece

Hexagon nut

ISO 4032-M8

8

18

1

Piece

Spring ring

DIN 127-A-8

A2

19

6

Piece

Hexagon screw

ISO 4017-M6x12

8.8

20

4

Piece

Rubber buffer

500029

GMT

21

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

22

2

Piece


G1/8

Spike

23

1

Piece

Radial shaft seal

DIN 3760-A16x35x7

NBR

24

2

Piece


DIN 625-6202

25

1

Piece


DIN 625-6203

Tab. 7.1

7 Solutions

Comments

Spare parts list

168

10/2008


MT 184


Item

Quanti ty

Unit

Name


Comments

26

1

Piece

Crosshead

MT184.10.04.002

EN-GJL-200

27

1

Piece

Piston Rod

MT184.10.04.003

X14CrMoS17

28

1

Piece

Straight pin

ISO 8734-12x35

C1

29

1

Piece

Hexagon nut

ISO 4032-M8

8-A2

30

1

Piece

Hexagon screw

ISO 4017-M6x25

8.8

31

1

Piece

Hexagon nut

ISO 4032-M6

8-A2

32

1

Piece


MT184.10.05.002

CuZn39Pb3

33

1

Piece

Brass washer

MT184.10.05.003

CuZn37F30

34

1

Piece

Gland packing

00.2251

Spike

35

1

Piece

Lip seal

ISO 4032-M8

A2-70

36

1

Piece

Lock nut

MT184.10.09.002

CuZn39Pb2

37

1

Piece

Knurled screw

MT184.10.08.003

CuZn39Pb3

38

1

Piece

Cap

MT184.10.08.004

NBR

39

1

Piece

Pump housing

MT184.10.06.001

EN-GJL-200

40

1

Piece

Cylinder cover

MT184.10.06.002

EN-GJL-200

41

1

Piece

Air chamber

MT184.10.06.003

EN-GJL-200

42

1

Piece

Water plug

MT184.10.06.004

CuZn39Pb2

43

1

Piece


MT184.10.06.005

9SMn28K

44

1

Piece

Cylinder pipe

MT184.10.06.006

X6CrNi18-10

45

1

Piece

Cap nut

DIN 1587-M12

CuZn39Pb3

46

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

47

1

Piece


SV.01-065.7,5 F3000.4

Spike

48

2

Piece


MT184.10.06.010

EN-GJL-200

49

1

Piece

Poppet valve body

MT184.10.08.001

50

2

Piece

Valve bridge

MT184.10.06.008

X14CrMoS17

51

1

Piece

Cylinder cover seal

MT184.10.06.009

SBR/B-870M

Tab. 7.1

7 Solutions

Spare parts list

169

10/2008


MT 184


Item

Quanti ty

Unit

Name


Comments

52

2

Piece

Flat washer

ISO 7089 -8

8-A2

53

2

Piece

Hexagon nut

ISO 4032-M8

8-A2

54

1

Piece

Air chamber seal

MT184.10.06.011

SBR/B-870M

55

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

56

2

Piece

Stud bolt

MT184.10.06.012

X17CrNi16-2

57

2

Piece

Stud bolt

MT184.10.06.013

X17CrNi16-2

58

2

Piece

Seal

DIN 7603-A13x18x1,5

PVC

59

4

Piece

Valve seat seal

MT184.10.06.014

SBR/B-870M

60

3

Piece

Hexagon screw

ISO 4017-M6x16

8.8-A2

61

3

Piece

Hexagon screw

ISO 4017-M8x25

8.8-A2

62

2

Piece

Seal

MT184.10.06.015

SBR/B-870M

63

1

Piece

Plain washer

MT184.10.06.016

X17CrNi16-2

64

1

Piece

Seal

DIN 7603-A13x18x1,5

PVC

65

1

Piece

Seal

DIN 7603-A39x49x2

EPDM

66

1

Piece

Valve seat

MT184.10.07.001

CuZn40Al2

67

1

Piece

Seal in valve seat

MT184.10.07.002

80 NBR 180

68

1

Piece


MT184.10.01.001

CuZn39Pb3

69

1

Piece


Mt184.10.01.002

CuZn39Pb3

70

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

71

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

72

1

Piece


MT184.10.02.001

CuZn39Pb3

73

1

Piece


MT184.10.02.002

CuZn39Pb3

74

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

Tab. 7.1

7 Solutions

Spare parts list

170

10/2008


MT 184


Item

Quanti ty

Unit

Name


Comments

75

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

76

1

Piece

Hexagon nut

ISO 10511.M6

A2

77

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

78

1

Piece

Rocker shaft

MT184.10.00.001

X14CrMoS17

79

1

Piece


MT184.10.00.002

X14CrMoS17

80

4

Piece

Insulating bush

MT184.10.00.003

GP-22

81

1

Piece


MT184.10.00.004

EN-GJL-200

82

1

Piece


MT184.10.00.005

EN-GJL-200

83

1

Piece

V-belt pulley

MT184.10.00.006

EN-GJL-200

84

1

Piece

Hexagon screw

ISO 4017-M8x25

8.8

85

5

Piece

Hexagon nut

ISO 4032-M8

8

86

2

Piece

Flat washer

ISO 7089-A-8

140 HV

87

3

Piece

Hexagon screw

ISO 4017-M6x-10

8.8

88

1

Piece


MT184.00.06.000

89

1

Piece

Crankcase complete

MT184.00.09.000

90

1

Piece


MT184.00.01.000

91

1

Piece


MT184.00.02.000

92

1

Piece

Valve seat

MT184.00.07.000

Tab. 7.1

7 Solutions

Spare parts list

171

10/2008

MT 184

7.2


Worksheet 1: Introduction to the piston pump, page 1 Objective: To obtain an overview of the design and function of the piston pump.

Exercise:


You are provided with an assembled pump. Dismantle the pump so that all the component parts are laid out before you.

7 Solutions

172

10/2008

MT 184


Worksheet 1, page 2


Pick up the pump drawings and the parts list. Locate the components in the drawings. Refer to the parts list to find out the correct names of the components.

7 Solutions

173

10/2008

MT 184


Worksheet 1, page 3 You are now familiar enough with the overall design of the pump to be able to answer the following questions: 1. With what type of displacement device is the pump fitted? With a dual sleeved piston. 2. Does a piston pump have a specific direction of rotation? Or are clockwise and anti-clockwise both possible?


The pump delivery is independent of the direction of rotation of the drive. However, optimum lubrication of the gearbox can only be effected in the direction indicated by the arrow on the pump. 3. Can you explain the basic operating principle of a piston pump? The enlargement of the delivery chamber creates a negative pressure and the pumped liquid is drawn in via the intake valve. The subsequent reversal of stroke reduces the size of the pump chamber and the piston displaces the liquid by way of the pressure valve. 4. Look at the materials in the parts list. For which media could the pump be suitable? Because of the materials used in it, the piston pump is used in particular to pump non-aggressive, fluid media, such as drinking water and domestic water.

7 Solutions

174

10/2008

MT 184

7.3


Worksheet 2: Design, function and applications of the piston pump, page 1 Objective: To explain the design of the pump. To understand and describe its method of operation and usage. Exercise: 1. Describe the design of the pump.


Use the drawings. The motor is mounted on the pump unit by clamp rails. The crankshaft, the connecting rod and the crosshead are automatically lubricated in the gearbox housing by circulating oil on every rotation. The piston rod is sealed off from the delivery chamber by a packing gland. The sleeved pistons made of NBR rubber run in a stainless steel cylinder bushing. The two delivery chambers each contain two disk valves with valve rubber plates. The delivery side of the pump is executed as an air chamber with a builtin safety valve. 2. Name the five key components. Pump housing, gearbox housing, valves, piston, packing gland.

7 Solutions

175

10/2008

MT 184


Worksheet 2, page 2 3. Explain the method of operation of the pump. Explain the delivery principle. On every revolution, the crankshaft acts by way of the connecting rod and the crosshead on the piston, which is mounted on the end of the piston rod. This stroke motion causes the piston to move back and forth in the cylinder bushing.


On every stroke the piston enlarges and reduces the size of the delivery chamber. In the enlarging delivery chamber a negative pressure is created, causing the pressure valve to close and liquid to flow via the intake valve into the delivery chamber. In the reducing delivery chamber the piston presses the liquid via the pressure valve out of the pump body, while at the same time the intake valve is pressed closed. 4. In what areas is the piston pump used? Piston pumps are used primarily to transport fluids at high delivery pressures and low flow rates. Typical applications include pumping drinking water and domestic water in residential areas, in agriculture, onboard ships, in industry and at commercial garden centres.

7 Solutions

176

10/2008

MT 184

7.4


Worksheet 3: Identifying causes of faults, page 1 Objective: To identify or suspect likely causes of faults in response to specific malfunctions while the pump is operating. Exercise:


Try to find the causes of the faults listed in the table below. Note down your assumptions in the right-hand section of the table. You can exclude systemrelated disturbances. Fault

Suspected cause

Medium leaking from pump body

Packing gland worn Housing seals defective

Running noise has markedly increased

Bearing damaged Crankshaft or piston rod deformed Oil filling too low

The pressure difference usually generated between the inlet and outlet is no longer being attained The pressure difference is much less than normal The pump housing has a much higher surface temperature than normal

Pump valves leaking Foreign bodies in the pump Piston worn

Crankshaft, bearing and crosshead damaged Oil filling too low

The current consumption of the drive motor has increased significantly compared to normal operating conditions

Motor defective

Service life of piston too short

Foreign bodies in the pump

Gearbox components defective

Dry running Inadequate material resistance

7 Solutions

177

10/2008

MT 184

7.5


Worksheet 4: Sealing systems, page 1 Objective: To divide sealing systems into basic categories and identify them based on the example of the pistons. Information: Sealing systems we can find in pumps are classified as follows:


Sealing systems

7 Solutions

Static seals

Dynamic seals

(seals subject to stationary stress)

(seals subject to motion)

178

10/2008

MT 184


Worksheet 4, page 2 Exercise: 1. Here you see the sectional drawing of the pump. • In the sectional drawing, mark the static seals as S and the dynamic seals as D. • What functions do the static and dynamic seals perform? The static seals seal the housing.


The dynamic seals seal moving parts.

S

D

7 Solutions

179

10/2008

MT 184


Worksheet 4, page 3 When you have identified the sealing systems used in the piston pump, move on to the following exercise. 2. Describe the design and method of operation of a shaft seal based on the floating ring principle.


Floating ring seals are contact seals which create a yielding seal connection between stationary and rotating contact faces. There is a film of liquid between these contact surfaces. The film of liquid assumes a stable position due to the centrifugal force occurring during rotation. Static elastomer seals seal the floating ring seal from the housing. The rotating floating ring is held axially to the counter ring by a spring, which is fixed in the housing. 3. Look at a shaft seal based on the packing gland principle and describe it. The gland packing is a woven cord mainly made of solid fabrics. It is deformed in the packing space between the shaft and the housing by an axial force and so pressed onto the surfaces being sealed. A sleeve is fitted to protect the shaft. Locking rings or ancillary glands hold the packing in place. The gland press compresses the packing by way of screw fittings.

7 Solutions

180

10/2008

MT 184

7.6


Worksheet 5: Inspection of pumps, page 1 Objective: To know what the term “inspection” involves, and to draw up an inspection plan.

Exercise:


1. What does the term “inspection” mean in the context of technical maintenance? Mark the statements you consider to be true or false in the Yes or No column of the following table as appropriate.

Activity The current actual status of a pump is recorded and assessed

Yes X

Components such as pistons or seals are replaced as a preventive maintenance measure

X

Shaft bearings are lubricated and couplings re-aligned

X

Entire pump units are replaced

X

An inspection is always carried out with the system stopped

X

During an inspection operating data of the pump system are measured (read) and entered in an inspection plan

X

An inspection can be seen as equivalent to preventive repair Inspection is a routine operation in machinery and plant maintenance

7 Solutions

No

X X

181

10/2008

MT 184


Worksheet 5, page 2 When you have established what the term “inspection” means, move on to the following exercise. 2. Imagine we were talking about a vital piston pump in a domestic water process. Let’s also assume that this pump is similar in design to the pump from our MT 184 practice kit.


Draw up an inspection plan by mean of which an inspection can be documented.

Inspection plan Pump:

Inspected by:

Serial no.:

Date:

Item

Comments

Pump capacity Delivery pressure Leakage Noise Smooth running Temperature General condition Oil level

7 Solutions

182

10/2008

MT 184

7.7


Worksheet 6: Servicing of pumps, page 1 Objective: To know what is meant by the term “servicing”. Exercise: 1. What does the term “servicing” mean in the context of technical maintenance?


Mark the statements you consider to be true or false in the Yes or No column of the following table as appropriate.

Activity

Yes

Components such as pistons, rod seals and gaskets are replaced as a preventive maintenance measure

X

The object of servicing is to record and assess the current actual status of a pump

X

Servicing of a pump is a routine operation, carried out at predetermined intervals

X

A service is usually carried out with the system stopped

X

Servicing can be seen as equivalent to preventive repair During a service, packing glands are repositioned, couplings adjusted or oil fillings changed for example

7 Solutions

No

X X


X

Servicing is always carried out when damage to a pump is identified

X

183

10/2008

MT 184


Worksheet 6, page 2 When you have established what the term “servicing” means, move on to the following exercise. 2. Do you think that routine servicing is useful and necessary for the piston pump from our MT 184 practice kit? Give reasons for your decision.


Yes! During servicing, the condition of the wearing parts is checked and the parts are replaced as necessary. For the piston pump from MT 184 the parts are the piston, the housing seals, the valves, the packing gland and the oil filling of the main gearbox. 3. Let’s assume that two piston pumps with the classic differing shaft seals are being used in a domestic water process. What servicing operations need to be carried out on the packing gland type shaft seal and on the floating ring seal type? Packing glands must be repositioned depending on the leakage rate. Their general condition must be checked and they must be repacked as necessary. Floating ring seals do not have to be adjusted. However, at each service the condition should be checked and, depending on the importance, replaced as a preventive measure.

7 Solutions

184

10/2008

MT 184

7.8


Worksheet 7: Repairs to pumps, page 1 Objective: To know what is meant by the term “repairs” in this context and to draw up a preventive maintenance plan.

Exercise:


1. What does the term “repairs” mean in the context of technical maintenance? Mark the statements you consider to be true or false in the Yes or No column of the following table as appropriate.

Activity Repairs involve replacing well-used parts with new ones, for example pistons and seals

Yes X

Repairs are carried out when damage has occurred to the pump Repairs may also be carried out as routine and preventive maintenance measures to prevent damage and stoppages from occurring in the first place

X X


7 Solutions

X

Preventive maintenance can prevent a pump from failing

X

Repairs are normally carried out with the system stopped

X

If servicing is carried out on a regular basis, repairs are not needed

No

X

185

10/2008

MT 184


Worksheet 7, page 2 When you have established what the term “repairs” means, move on to the following exercise. 2. Let us assume that our piston pump represents an important assembly in a domestic water process. A failure of the pump would result in the entire line being shut down. In view of this, the pump is inspected and serviced at regular intervals.


To achieve the most reliable operation possible, the plant management decides to carry out routine preventive repairs to the unit. Draw up a repair order for carrying out and documenting the work. Use the drawings. Inspection order Pump:

Inspected by:

Serial no.:

Date:

Procedure

Comments/Status

Parts to be replaced: Valve rubber plate (70, 74) Valve seat seal (59) Air chamber seal (54) Connection seals (62) Cylinder cover seals (51) Piston (14) Packing gland packs (34) Lip seal (35) Oil filling Parts to be checked: Housing components Bearings Piston Rod

7 Solutions

186

10/2008

MT 184

7.9


Worksheet 8: Wearing parts on the piston pump, page 1 Objective: To identify the wearing parts on the piston pump. Exercise: 1. Mark the wearing parts on the pump drawing and name them by way of example. Cylinder seal

Connection seal

Valve seat seal


Air chamber seal

Gland packing

7 Solutions

Lip seal

Piston

Valve rubber plate

187

10/2008

MT 184


Worksheet 8, page 2

2. Of what material are the wearing parts of the piston pump made?


Enter the wearing parts from the previous page in the table with their material data or standard designations.

7 Solutions

Wearing part

Material

Gland packing

PTFE-saturated

Lip seal

A2 - 70

Piston

NBR

Valve rubber plate

NBR-45° Shore A

Air chamber seal, cylinder seal, connection seal, valve seat seal

SBR/B-870M

188

10/2008

MT 184

7.10


Worksheet 9: Assembling the piston pump, page 1 Objective: To structure the assembly process. To identify which assembly units and phases can be compiled. Exercise: You have laid out all the component parts of the piston pump in front of you. Your task is to assemble the pump.


To do this, first assembly individual assembly units. Then combine the assembly units to create the overall system in a sequence of assembly phases. 1. Collect the components from which you can compile assembly units and phases. Name the assembly units and phases. Use the drawings.

• Assembly unit 1 – Crankshaft

7 Solutions

Item

Name

3

Crankshaft

24


25


189

10/2008

MT 184


Worksheet 9, page 2


• Assembly unit 2 – Connecting rod with piston rod Item

Name

1

Connecting rod

26

Crosshead

27

Piston Rod

28

Straight pin

29

Hexagon nut

30

Hexagon screw

31

Hexagon nut

• Assembly unit 3 – Packing gland Item

Name

2


32

Packing gland screw

33

Brass washer

34

Gland packing

35

Lip seal

• Assembly unit 4 – Intake valve

7 Solutions

Item

Name

72


73


74

Valve rubber plate

75

Hold-down

76

Hexagon nut

190

10/2008

MT 184


Worksheet 9, page 3


• Assembly unit 5 – Pressure valve Item

Name

68


69


70

Valve rubber plate

71

Hold-down

• Assembly unit 6 – Gearbox

7 Solutions

Item

Name

A

Assembly unit 1

B

Assembly unit 2

C

Assembly unit 3

5

Gearbox housing

6


7

Gearbox cover

9

Oil splash guard

10

Packing gland seal

11

Bearing cover seal

12

Oil stripper

13

Oil plug

14

Duo-piston

17

Hexagon nut

18

Spring ring

19

Hexagon screw

21, 22

Angled oiler with nut and seal

4, 23


191

10/2008

MT 184


Worksheet 9, page 4


• Assembly unit 7 – Pump housing

7 Solutions

Item

Name

D

Assembly unit 4

E

Assembly unit 5

40

Cylinder cover

41

Air chamber

42, 58

Water plug with seal

43


54

Air chamber seal

59

Valve seat seal

60

Hexagon screws

61

Hexagon screws

62

Seal

45, 63

Cap nut with washer

46, 77

Drain plug with seal

47, 65

Membrane safety valve with seal

48


49, 64

Poppet valve body with seal

50

Valve bridge

51

Cylinder cover seal

52, 53

Hexagon nut with washer

192

10/2008

MT 184


Worksheet 9, page 5

2. When you have put together the various assembly units, the next step is to assemble the pump. You should carry out this phase and represent it in a structure corresponding to the pattern shown.


Set out the identified assembly phases through to the complete pump.

Gearing

Parts x, y, ...

Parts x, y, ...

Piston pump

7 Solutions

193

10/2008

MT 184


Worksheet 9, page 6 Procedure for assembling the piston pump Gearbox (assembly unit 6)



Hexagon nut with washer (item 85, 86) Disk spring (item 15) V-belt pulley with hexagon screw (item 83, 87) Rocker shaft (item 78) Motor clamp rail left and right (item 81, 82) Hexagon screw item 87 Rocker shaft with gearbox (item 79) Hexagon screw with hexagon nut (item 84, 85)

Piston pump

7 Solutions

194

10/2008

MT 184

7.11


Worksheet 10: Piston replacement, page 1 Objective: Planning and execution of piston replacement on a piston pump. Exercise: 1. Your task is to replace the piston on a piston pump.


Set out your method in the pre-compiled work plan. Use the drawings.

7 Solutions

195

10/2008

MT 184



Work plan Name: Piston pump – Piston replacement Date:

Carried out by:

Order no.:

Date:

Proced ure

Procedure

Tools


Dismantling 1

Unscrew hexagon nut and washer (85, 86) from stud bolts and detach packing gland (assembly unit 3) from pump

Wrench size 13

2

Unscrew hexagon nut (85) from stud bolts

Wrench size 13

3

Pull pump housing (assembly unit 7) from gearbox (assembly unit 6). Carefully guide piston out of cylinder pipe when doing so

4

Unscrew hexagon nut with spring ring (17, 18) from duo- Wrench size 13 piston (14)

5

Pull duo-piston from piston rod (27)

Assembly 6

Fit duo-piston onto piston rod

7

Screw hexagon nut with spring ring (17, 18) against duo- Wrench size 13 piston

8

Grease piston Place pump housing (assembly unit 7) against gearbox (assembly unit 6). Carefully guide piston into cylinder pipe when doing so

9

Screw together pump housing and gearbox with hexagon nut (85) and pre-assembled stud bolts

Wrench size 13

10

Fit packing gland (assembly unit 3) with hexagon nut and washer (85, 86) on stud bolts

Wrench size 13

Estimated time required: 20 min

7 Solutions

196

10/2008

MT 184

7.12


Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1 Objective: To assign items from a spare parts list to a spare parts drawing. Exercise: You are given a spare parts drawing on which the item numbers have not yet been entered. Refer to the supplied spare parts list.


Enter the item numbers from the 1st column of the spare parts list in the fields in the spare parts drawing.

7 Solutions

197

10/2008

MT 184


83, 87

81, 82

79, 80

84, 85

87

79, 80

85, 86


8


Fig. 7.4

7 Solutions


198

10/2008

MT 184


Worksheet 11, page 3 11 19

4, 23

6 3 - 15

22 All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 10/2008

21

16

7 1 30,31 24 25 5 26 28 13

29

9

27 12

32 2 33 18 17

35 34

14

10 20 8

Fig. 7.5

7 Solutions


199

57

42 58

Fig. 7.6

7 Solutions 44

60

36

64

51 38 49 37

40

43

59

70

71

54 68

39

50, 52, 53

41

69

67 47

73 74

72

62

48

47

75 46, 77 76

65

61

MT 184

63

45

58 66


10/2008




200

10/2008

MT 184




Quanti ty

Unit

Name


1

1

Piece

Connecting rod

MT184.10.04.001

2

1

Piece


MT184.10.05.002

3

1

Piece

Crankshaft

MT184.10.03.001

4

1

Piece

Bearing cover, open

MT184.10.10.001

5

1

Piece

Gearbox housing

MT184.10.09.001

EN-GJL-200

6

1

Piece


MT184.10.09.002

EN-GJL-200

7

1

Piece

Gearbox cover

MT184.10.09.003

DOC04

8

1

Piece

Base plate

MT184.10.09.004

S235JR

9

1

Piece

Oil splash guard

MT184.10.09.005

DOC04

10

1

Piece

Packing gland seal

MT184.10.09.006

SBR/B-870M

11

2

Piece

Bearing cover seal

MT184.10.09.007

SBR/B-870M

12

1

Piece

Oil stripper

MT184.10.09.008

60NBR693 SW

13

1

Piece

Oil plug

MT184.10.09.009

CuZn39Pb3

14

1

Piece

Duo-piston

PM10

Simirit

15

1

Piece

Disk spring

DIN 6888-5x7,5

16

8

Piece

Hexagon nut

ISO 4032-M6

8

17

2

Piece

Hexagon nut

ISO 4032-M8

8

18

1

Piece

Spring ring

DIN 127-A-8

A2

19

6

Piece

Hexagon screw

ISO 4017-M6x12

8.8

20

4

Piece

Rubber buffer

500029

GMT

21

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

22

2

Piece


G1/8

Spike

23

1

Piece

Radial shaft seal

DIN 3760-A16x35x7

NBR

24

2

Piece


DIN 625-6202

25

1

Piece


DIN 625-6203

Tab. 7.2

7 Solutions

Comments

Spare parts list

201

10/2008

MT 184




Quanti ty

Unit

Name


Comments

26

1

Piece

Crosshead

MT184.10.04.002

EN-GJL-200

27

1

Piece

Piston Rod

MT184.10.04.003

X14CrMoS17

28

1

Piece

Straight pin

ISO 8734-12x35

C1

29

1

Piece

Hexagon nut

ISO 4032-M8

8-A2

30

1

Piece

Hexagon screw

ISO 4017-M6x25

8.8

31

1

Piece

Hexagon nut

ISO 4032-M6

8-A2

32

1

Piece


MT184.10.05.002

CuZn39Pb3

33

1

Piece

Brass washer

MT184.10.05.003

CuZn37F30

34

1

Piece

Gland packing

00.2251

Spike

35

1

Piece

Lip seal

ISO 4032-M8

A2-70

36

1

Piece

Lock nut

MT184.10.09.002

CuZn39Pb2

37

1

Piece

Knurled screw

MT184.10.08.003

CuZn39Pb3

38

1

Piece

Cap

MT184.10.08.004

NBR

39

1

Piece

Pump housing

MT184.10.06.001

EN-GJL-200

40

1

Piece

Cylinder cover

MT184.10.06.002

EN-GJL-200

41

1

Piece

Air chamber

MT184.10.06.003

EN-GJL-200

42

1

Piece

Water plug

MT184.10.06.004

CuZn39Pb2

43

1

Piece


MT184.10.06.005

9SMn28K

44

1

Piece

Cylinder pipe

MT184.10.06.006

X6CrNi18-10

45

1

Piece

Cap nut

DIN 1587-M12

CuZn39Pb3

46

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

47

1

Piece


SV.01-065.7,5 F3000.4

Spike

48

2

Piece


MT184.10.06.010

EN-GJL-200

49

1

Piece

Poppet valve body

MT184.10.08.001

50

2

Piece

Valve bridge

MT184.10.06.008

Tab. 7.3

7 Solutions

X14CrMoS17

Spare parts list

202

10/2008

MT 184




Quanti ty

Unit

Name


Comments

51

1

Piece

Cylinder cover seal

MT184.10.06.009

SBR/B-870M

52

2

Piece

Flat washer

ISO 7089 -8

8-A2

53

2

Piece

Hexagon nut

ISO 4032-M8

8-A2

54

1

Piece

Air chamber seal

MT184.10.06.011

SBR/B-870M

55

2

Piece

Seal

DIN 7603-A10x13,5x2

PVC

56

2

Piece

Stud bolt

MT184.10.06.012

X17CrNi16-2

57

2

Piece

Stud bolt

MT184.10.06.013

X17CrNi16-2

58

2

Piece

Seal

DIN 7603-A13x18x1,5

PVC

59

4

Piece

Valve seat seal

MT184.10.06.014

SBR/B-870M

60

3

Piece

Hexagon screw

ISO 4017-M6x16

8.8-A2

61

3

Piece

Hexagon screw

ISO 4017-M8x25

8.8-A2

62

2

Piece

Seal

MT184.10.06.015

SBR/B-870M

63

1

Piece

Plain washer

MT184.10.06.016

X17CrNi16-2

64

1

Piece

Seal

DIN 7603-A13x18x1,5

PVC

65

1

Piece

Seal

DIN 7603-A39x49x2

EPDM

66

1

Piece

Valve seat

MT184.10.07.001

CuZn40Al2

67

1

Piece

Seal in valve seat

MT184.10.07.002

80 NBR 180

68

1

Piece


MT184.10.01.001

CuZn39Pb3

69

1

Piece


Mt184.10.01.002

CuZn39Pb3

70

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

71

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

72

1

Piece


MT184.10.02.001

CuZn39Pb3

73

1

Piece


MT184.10.02.002

CuZn39Pb3

Tab. 7.4

7 Solutions

Spare parts list

203

10/2008

MT 184




Quanti ty

Unit

Name


Comments

74

1

Piece

Valve rubber plate

MT184.10.01.003

NBR-45° Shore A

75

1

Piece

Hold-down

MT184.10.01.004

CuZn39Pb3

76

1

Piece

Hexagon nut

ISO 10511.M6

A2

77

1

Piece

Drain plug

MT184.10.06.007

CuZn39Pb2

78

1

Piece

Rocker shaft

MT184.10.00.001

X14CrMoS17

79

1

Piece


MT184.10.00.002

X14CrMoS17

80

4

Piece

Insulating bush

MT184.10.00.003

GP-22

81

1

Piece


MT184.10.00.004

EN-GJL-200

82

1

Piece


MT184.10.00.005

EN-GJL-200

83

1

Piece

V-belt pulley

MT184.10.00.006

EN-GJL-200

84

1

Piece

Hexagon screw

ISO 4017-M8x25

8.8

85

5

Piece

Hexagon nut

ISO 4032-M8

8

86

2

Piece

Flat washer

ISO 7089-A-8

140 HV

87

3

Piece

Hexagon screw

ISO 4017-M6x-10

8.8

88

1

Piece


MT184.00.06.000

89

1

Piece

Crankcase complete

MT184.00.09.000

90

1

Piece


MT184.00.01.000

91

1

Piece


MT184.00.02.000

92

1

Piece

Valve seat

MT184.00.07.000

Tab. 7.5

7 Solutions

Spare parts list

204

10/2008

MT 184

7.13


Worksheet 12: Spare parts ordering, page 1 Objective: To place a technically unambiguous spare parts order.

Exercise: You are going to carry out a repair, and need replacement parts for your piston pump. All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 10/2008

Select three parts and make a spare parts order. Use the documents provided.

Spare parts order for pump: Type:

PM 10

Serial no.:

Parts:

7 Solutions

1x

duo-piston

Item 14

4x

valve rubber plate

Item 70

1 set of

gland packs

Item 34

205

10/2008

MT 184

8


Index

A


Assembly phase 1 – Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 120 Assembly phase 2 – Connecting rod with piston rod . . . . . . . . . . 65, 119 Assembly phase 3 – Packing gland . . . . . . . . . . . . . . . . . . . . . . . 69, 118 Assembly phase 4 – Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . 73, 117 Assembly phase 5 – Pressure valve . . . . . . . . . . . . . . . . . . . . . . . 77, 116 Assembly phase 6 – Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81, 113 Assembly phase 7 – Pump housing . . . . . . . . . . . . . . . . . . . . . . . 91, 110 Assembly phase 8 – Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 107 C Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 8, 29 Centrifugal pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29 Characteristic curve, pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Characteristic curve, system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 D Diaphragm pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 11, 30 Dynamic seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F Floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 G Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14, 32 H Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I Inline centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 13, 31 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Intake characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8 Index

206

10/2008

MT 184


M Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Multi-flow pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Multiple-stage pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Multi-stage centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29 O Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17


P Packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Parallel configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 12, 31, 46, 59 Piston pump dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Piston pump spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Piston pump spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Piston rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 41 Piston seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Positive-displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14 Pump characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Pump, multi-flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 R Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 34 Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 S Screw pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 10, 30 Seals, dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Seals, floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Seals, packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 49 Seals, static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Series configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Standard centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 System characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 Index

207

10/2008

MT 184


T Technical data of piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 V


Valves in pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8 Index

208

10/2008

MT 184


9

9 Drawings


Drawings Name

Drawing number

Layout

MT184.00.00.000

Spare parts list

MT184.00.00.000

Piston pump – Drawing

MT184.00.00.000

Piston pump – Parts list

MT184.00.00.000

Pressure valve, complete – Drawing

MT184.00.01.000

Pressure valve, complete – Parts list

MT184.00.01.000

Intake valve, complete – Drawing

MT184.00.02.000

Intake valve, complete – Parts list

MT184.00.02.000

Crankshaft with bearing – Drawing

MT184.00.03.000

Crankshaft with bearing – Parts list

MT184.00.03.000

Connecting rod with piston – Drawing

MT184.00.04.000

Connecting rod with piston – Parts list

MT184.00.04.000

Packing gland complete – Drawing

MT184.00.05.000

Packing gland complete – Parts list

MT184.00.05.000

Valve housing complete – Drawing

MT184.00.06.000

Valve housing complete – Parts list

MT184.00.06.000

Seat valve – Drawing

MT184.00.07.000

Seat valve – Parts list

MT184.00.07.000

Poppet valve – Drawing

MT184.00.08.000

Poppet valve – Parts list

MT184.00.08.000

Crankcase, complete – Drawing

MT184.00.09.000

Crankcase, complete – Parts list

MT184.00.09.000

Flange with seal – Drawing

MT184.00.10.000

Flange with seal – Parts list

MT184.00.10.000

Rocker shaft

MT184.10.00.001


MT184.10.00.002

Insulating bush for motor rockers

MT184.10.00.003

209

10/2008


MT 184

9 Drawings


Name

Drawing number


MT184.10.00.004


MT184.10.00.005

Pump V-belt rail

MT184.10.00.006


MT184.10.01.001


MT184.10.01.002

Valve rubber plate

MT184.10.01.003

Hold-down

MT184.10.01.004


MT184.10.02.001

Crankshaft

MT184.10.03.001

Connecting rod

MT184.10.04.001

Crosshead

MT184.10.04.002

Piston Rod

MT184.10.04.003


MT184.10.05.001

Packing gland screw

MT184.10.05.002

Brass washer

MT184.10.05.003

Valve housing

MT184.10.06.001

Cylinder cover

MT184.10.06.002

Air chamber

MT184.10.06.003

Water plug

MT184.10.06.004


MT184.10.06.005

Cylinder pipe

MT184.10.06.006

Oil plug

MT184.10.06.007

Valve bridge

MT184.10.06.008

Cylinder cover seal

MT184.10.06.009


MT184.10.06.010

Air chamber seal

MT184.10.06.011

Stud bolt

MT184.10.06.012

Stud bolt

MT184.10.06.013

210

10/2008


MT 184

9 Drawings


Name

Drawing number

Valve seat seal

MT184.10.06.014

Flange seal

MT184.10.06.015

Plain washer

MT184.10.06.016

Valve seat

MT184.10.07.001

Seal in safety valve seat

MT184.10.07.002

Poppet valve body

MT184.10.08.001

Lock nut for poppet valve

MT184.10.08.002

Knurled screw for poppet valve

MT184.10.08.003

Cap

MT184.10.08.004

Drive frame

MT184.10.09.001


MT184.10.09.002

Gearbox cover

MT184.10.09.003

Base plate

MT184.10.09.004

Oil splash guard

MT184.10.09.005

Seal for packing gland

MT184.10.09.006

Bearing cover seal

MT184.10.09.007

Oil stripper

MT184.10.09.008

Oil plug without thread

MT184.10.09.009

Bearing cover, open

MT184.10.10.001

211

MT184CP

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