Universal 5000 Industrial Series - Hayward Gordon · 6 95-03012 2. Good Piping Practice. All piping to the pump should be supported independently, to minimize the forces exerted on

Universal 5000 Industrial SeriesROTARY POS ITIVE D I S PLACE M E NT PU M P

FOR M NO.: 95-03012 R EVI S ION: 12/2015 R EAD AN D U N D E R STAN D TH I S MAN UAL PR IOR TO OPE RATI NG OR S E RVICI NG TH I S PROD UCT.

I N STR UCTION MAN UAL

Information contained in this manual is subject to change without notice and does not represent a commitment on the part of SPX FLOW, Inc. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose, without the express written per-mission of SPX FLOW, Inc.

Copyright © 2015 SPX FLOW, Inc.

All Rights Reserved.

Revision Date: 12/2015

Publication: 95-03012

SPX FLOW, Inc.611 Sugar Creek Road

Delavan, WI 53115 USA

Tel: (800) 252-5200 or (262) 728-1900Fax: (800) 252-5012 or (262) 728-4904

E-mail: [email protected] site: www.spxflow.com

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egaP NOITCES egaP NOITCES

TABLE OF CONTENTS

Fluid Head Assembly ............................... 32Packing Seals and Body .............................. 32Mechanical Seals and Body ........................ 32-33

Typical Flush Piping ............................................ 33

Rotor ClearancesBack Face ................................................ 34Rotor to Body ........................................... 34Front Face ................................................ 34

X Reference Tables .Table 1. Standard Rotor Clearance ............. 35Table 2. Assembly Torque Values .............. 35Table 3. Suggested Shims .......................... 35Table 4. Hydraulic Press Tonnage .............. 35

XI Waukesha Internal By-Pass Relief Valve 36-37

XII Universal Industrial Parts Lists5040 Pump ............................................... 38-395040 Standard Seals ................................ 485050 Pump ............................................... 40-415050 Standard Seals ................................ 495060 Pump ............................................... 42-435060 Standard Seals ................................ 505070 Pump ............................................... 44-455070 Standard Seals ................................ 515080 Pump ............................................... 46-475080 Standard Seals ................................ 52

XIII Stuffing Box Dimensions......................... 53

WARNING LABEL REPLACEMENT .................... 54

Safety .......................................................... 2

I Receiving and Warranty......... .................. 3

ll Installation.................................... ............. 4

lll Start-up Check List ............................ ...... 10

IV Troubleshooting a Pump System ... ......... 11-14

V Operation ...................................... ............ 15

Vl Maintenance .................................... ......... 16Visual Checks ........................................... 16Feel Checks ............................................. 17Seal Maintenance .................................... 18Packing Seals ........................................... 18Mechanical Seals ..................................... 19

Annual Maintenance .................................. 20

VlI Factory Reconditioning ......................... .. 21

Vlll Disassembly ProceduresFluid HeadCover Removal ......................................... 21Rotor Removal ......................................... 22Body and Seal Removal ........................... 22Shaft, Bearings and Gear Removal ......... 23-25

IX Assembly ProceduresShaft Assembly

Front Bearing, 5040 ................................. 26Front Bearing, 5050, 5060, 5070, 5080 ... 27Rear Bearing, All Models ......................... 28

Gear Case Assembly ................................... 29Front Bearing Grease Seals- 5080 OnlyShims - All Models ................................... 29Shaft Installation (All Models) .................. 29Bearing Retainer Adjustment ................... 29-30Rear Seal Assembly ................................. 30

Timing Gear and Cover Assembly ............... 31

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SAFETY

Warnings, cautions and notes are contained in this manual. To avoid serious injury and/or possible damage to equipment, pay attention to these messages.

WARNING Hazards or unsafe practices which COULD resultin severe personal injury or death and how to avoid it.

CAUTION Hazards or unsafe practices which COULD resultin minor personal injury or product or property damage.

NOTE Important information pertaining directly to the subject.(Information to be aware of when completing the task.)

Read and understand this manual prior toinstalling, operating or maintaining this pump.

REPLACEMENT LABELSee Page 57

REPLACEMENT LABELSee Page 57

WARNINGTO AVOID SERIOUS INJURY, DO NOT

INSTALL OR SERVICE PUMP UNLESSALL POWER IS OFF AND LOCKED OUT.

WARNINGTO AVOID POSSIBLE SERIOUS INJURY,

SHUT OFF AND DRAIN PRODUCT FROMPUMP PRIOR TO DISCONNECTING PIPING.

WARNINGDO NOT OPERATE

WITHOUT GUARD IN PLACE

Stop Machinery to Clean,Service or Repair

WARNING

SEE PAGE 57 FOR LABEL PLACEMENT

WARNINGTo avoid electrocution, ALL electrical should be

done by a registered Electrician, followingIndustry Safety Standards.

All power must be OFF and LOCKED OUT

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FACTORY INSPECTIONEach WAUKESHA pump is shipped completely assembled, lubricated and ready for use. (See OPERA-TION on page 15). The WAUKESHA pump is a precision product, designed to provide long, trouble-freeservice in a properly designed system with normal maintenance.

RECEIVING INSPECTIONPorts are covered at the factory to keep out foreign objects. If covers are missing or damaged, a thor-ough inspection of fluid head, by removing pump cover, is recommended. Be sure pumping head isclean and free of foreign material before rotating shaft.

LOSS OR DAMAGEIf your pump has been lost or damaged in transit, file a claim at once with the delivering carrier and askfor an Inspector to call. The carrier has signed the Bill of Lading acknowledging that the shipment hasbeen received from us in good condition.We will of course assist you in every way in collecting claims for loss, or damage, however, we are notresponsible for the collection of claims or replacement of material.

WARRANTYPlease read the Warranty statement to correctly determine if you have a claim. In warranty claims youmust have a "Returned Goods Authorization" (RGA) from the manufacturer before any returns will beaccepted. Your Distributor will help you in a warranty problem. (See page 55 for Information required)

WAUKESHA CHERRY-BURRELL WARRANTYSeller warrants its products to be free from defects in materials and workmanship fora period of one (1) year from the date of shipment. This warranty shall not apply toproducts which require repair or replacement due to normal wear and tear or toproducts which are subjected to accident, misuse or improper maintenance. Thiswarranty extends only to the original Buyer. Products manufactured by others butfurnished by Seller are exempted from this warranty and are limited to the originalmanufacturer’s warranty.Seller’s sole obligation under this warranty shall be to repair or replace any productsthat Seller determines, in its discretion, to be defective. Seller reserves the right eitherto inspect the products in the field or to request their prepaid return to Seller. Sellershall not be responsible for any transportation charges, duty, taxes, freight, labor orother costs. The cost of removing and/or installing products which have been repairedor replaced shall be at Buyer’s expense.Seller expressly disclaims all other warranties, express or implied, including withoutlimitation any warranty of merchantability of fitness for a particular purpose. Theforegoing sets forth Sellers entire and exclusive liability, and Buyer’ exclusive and soleremedy, for any claim of damages in connection with the sale of products. In no eventshall Seller be liable for any special consequential incidental or indirect damages(including without limitation attorneys’ fees and expenses), nor shall Seller be liablefor any loss of profit or material arising out of or relating to the sale or operation ofthe products based on contract, tort (including negligence), strict liability or otherwise.

SECTION IRECEIVING AND WARRANTY

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SECTION IIINSTALLATION

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PUMP INSTALLATIONThe installation of your Waukesha pump and its piping system should follow the practices described togive optimum performance, and be in accordance with local codes and restrictions.

All system equipment, such as motors, sheaves, drive couplings, speed reducers, etc., must be properlysized to insure satisfactory operation of your Waukesha pump within its limits.

CAUTION: Waukesha pumps are positive displacement, low slip design and will beseverely damaged if operated with closed valves in discharge or inlet lines. Pump war-ranty is not valid for damages caused by a hydraulic overload from operation or start-upwith a closed valve in the system.

WARNINGFull coupling guards must be installed to isolate operators and maintenancepersonnel from rotating components. Coupling guards are provided withWaukesha pumps as a part of a complete pump and drive package.

1. Installing the Pump and Drive Unit. Pumps of this type and size are generally mounted on a commonbase plate with the drive.

The unit can be installed in the plant location in several ways:

Permanent installation on foundation with bolts andgrout. (Level unit before grouting.)

Many commercial types available.

Leveling and/or vibration isolation pads.

GUARD

GUARD

INSTALLATION

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2. Good Piping Practice.All piping to the pump should be supported independently, to minimize the forces exerted on the pump. Suchforces can cause misalignment of pump parts and lead to excessive wear of rotors, bearings and shafts.

NOTE: Pump dimensions and pump weights are on page 4.

Thermal expansion of piping-can cause tremendousforces. Use thermal expansion joints to minimizeforces on pump.

Flexible joints can also be used to limit the transmis-sion of mechanical vibration. Anchor free ends of anyflexible hose in system.

Portable bases-for movement to different locations.

Adjustable leg base, commonly used for sanitarypumps. For washdown under base. Can be easilymoved or repositioned.

Piping support:Weight of piping and fluid-support piping indepen-dently with hangers or pedestals.

GUARD

GUARD

WARNINGTO AVOID SERIOUS INJURY, DO NOTINSTALL OR SERVICE PUMP UNLESS

ALL POWER IS OFF AND LOCKED OUT.

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Piping LayoutInlet side: Slope piping up to inlet to avoid airpocket.

CORRECT

OUTLET INLET

WRONG

INLET

BY-PASS FLOW

OUTLETINLET

RELIEFVALVE

VALVEVALVE

''Isolation'' Valves-permit pump maintenance andremoval safely and without emptying entire systemrelief valve.

INLET

Inlet Vacuum Service-use check valve on outletside.• Prevents backflow (air or fluid).• Facilitates initial start-up (minimizes differential pressure pump must supply to start flow).

Inlet side-use check valves to keep inlet line full,particularly with low viscosity fluids, and in start-stop operation.

Relief ValveTo protect the pump and piping system againstexcessive pressure, a relief valve should be installed.An integral relief valve, designed to bypass the fluidinternally from the pump outlet to the inlet, shouldnot be used on applications where the dischargemust be closed for more than a few minutes.Prolonged operation of the pump with closed dis-charge will cause heating of the fluid circulatingthrough the relief valve. When such operation isnecessary, the relief valve, whether integral, attach-able, or line-mounted, should discharge externallythrough piping connected to the fluid source, or ifthat is not practical, into the inlet piping near thesource.

AIR POCKET

OUTLET

INLET

OUTLET

OUTLET

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A particular relief valve design will have a charac-teristic curve such as shown. The ''cracking pres-sure" can usually be set by spring adjustment, orby adjustable pneumatic pressure, etc. Flow willbegin to bypass when this ''cracking pressure'' isreached. As flow increases through the bypass, thesystem pressure will also increase.

The pressure increase for a given valve design depends on the valve setting, the flow rate, and theviscosity of the fluid being pumped. If the full-flow bypass pressure exceeds the maximum allowable forthe particular pump and piping system, an oversize attachable relief valve may sometimes be used tolimit the full-flow bypass pressure to an acceptable value.

Inlet Side-Strainers and Traps.Inlet side strainers and traps can be used to pre-vent pump damage from foreign matter. Selectionmust be carefully made as clogging can easilyoccur, restricting the inlet, causing cavitation andflow stoppage.

3. Alignment of Pump to Drive.Pumps and drives which are ordered from the factory and mounted on a common base plate are accu-rately aligned before shipment. The alignment should be rechecked after the complete unit has beeninstalled and the piping completed. Periodic rechecking is advisable during the pump service life.

CRACKINGPRESSURE

BY-PASSPRESSURE

Wherever possible-install gauges!!

STRAINER

FLOW

MAGNETIC TRAP

Pressure Gauges

Pressure and Vacuum gauges provide the easiestway to tell you something about the pump opera-tion.

• Normal or abnormal pressures• Overload conditions• Indication of flow• Changes in pump condition• Changes in system conditions• Changes in fluid viscosity

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CHECK AT 4 POINTS AROUNDCOUPLING-EVERY 90°

In-line Drives. For initial pump installation, and for rechecking alignment, the following steps areadvised:Use a flexible coupling to connect the drive to the pump. Many different types are available, includingcouplings with slip or overload provision.

FLUIDCOUPLING

SLIPOVERLOADDETENTFLEXIBLE

MEMBERGEARTYPE

RUBBERCUSHIONED

A flexible coupling is used to compensate for end play and small differences in alignment. Thepump and drive shaft should be aligned as closely as is possible.

Check angular alignment:Using feeler gauges, or taper gauges.Adjust to get equal dimension at all points. At thesame time set space between coupling halves tomanufacturer’s recommended distance.

FEELER OR TAPER GAUGE

SHIM ASNEEDED

Check parallel misalignment: Use straight edges and shims:

MOVE DRIVEAS NEEDED

SHIM HEIGHT AS NEEDED

After piping is complete, and drive and couplings are aligned, turn pump shaft manuallyto see if it turns freely without binding.

Note: Covers have been removed for illustration purposes only. The pumpcannot be operated with the cover removed.

TOP SHAFTDRIVE

LOWER SHAFTDRIVE

LOWER SHAFT DRIVE

TOP SHAFTDRIVE

Check rotation direction of drive to see that pump will rotate in proper direction.(“Liquid End” of pump is shown below.)

CONNECT COUPLING HALVES AND INSTALL COUPLING GUARD. Determine rotation direction by looking at the motor coupling.

Figure 1

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After piping is complete and before belts are installed, turn pump shaft manually to see that it turnsfreely.Check rotation direction of pump to see that pump will rotate in proper direction (see figure 1, page 9)

Install belts and tension them correctly. Install belt guard.

KEEP DISTANCETO MINIMUM

MOVE DRIVE TO CORRECT ANGULARAND PARALLEL MISALIGNMENT.

Aligning belt and chain drives. Using straight-edges and visual check:.

SECTION III

START-UP CHECK LISTThe Waukesha Pump is a positive displacement pump and thus can develop very high pressures.To protect lines, equipment and personnel, certain precautions must be taken.

1. Review Section II, page 7, particularly “Relief Valves". Install relief valves if needed in system.

2. Check that piping and pump are clean and free of foreign material, such as welding slag,gaskets, etc. Do not use pump to flush system.

3. See that all piping connections are tight and leak-free. Where possible, check system with“non-hazardous” fluid.

4. Check to see that pump and drive are lubricated. See Section V, page 15. Check DriveLubrication Instruction.

5. Check that all guards are in place and secure.

6 Seals: Double mechanical and double O-ring seals with flushing require adequate supply andflow of clean flushing fluids.

7. See that all valves are open on discharge system, and that free flow path is open todestination.

8. See that all valves are open on inlet side, and that fluid can reach pump.

9. Check direction of pump and drive rotation. (See page 9)

10. Start pump drive. Where possible, start at slow speed, or jog.

Check to see that liquid is reaching pump within several minutes. If pumping does not begin andstabilize, check items under “No Flow” or “Insufficient Flow” in Section IV, (Page 11)

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WARNINGTO AVOID POSSIBLE SERIOUS INJURY,SHUT OFF AND DRAIN PRODUCT FROM

PUMP PRIOR TO DISCONNECTING PIPING.

No flow, pump Drive motor not running Check resets, fuses, circuitnot turning breakers

Keys sheared or missing Replace

Drive belts, power transmission Replace or adjustcomponents slipping or broken

Pump shaft, keys, or gears Inspect: replace partssheared

No flow, pump Wrong direction of rotation Reverse directionturning

No flow, pump Valve closed in inlet line Open valvenot priming

Inlet line clogged or restricted Clear line, clean filters, etc.

Air leaks due to bad seals or pipe Replace seals; check lines forconnections leakage (can be done by air

pressure or by filling with liquidand pressurizing with air)

Pump speed too slow Increase speed. Filling inlet lineswith fluid may allow initialstart-up. Foot valve may solvestart-up problems permanently.

Liquid drains or siphons from Use foot valve or check valvessystem during off periods

SECTION IVTROUBLESHOOTING A PUMPING SYSTEM

Once a pump is properly selected and installed in a system, operation should be trouble free. However, inexisting systems, or as pump and system conditions change, problems may develop. Following are sometroubleshooting hints to help identify and solve problems.

Problem Probable Causes Solutions

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No flow, pump "Air" lock. Fluids which "gas off", Manual or automatic air bleed fromnot priming or vaporize, or allow gas to come pump or lines near pump

out of solution during off periods

Extra clearance rotors, worn pump Increase pump speed, use footvalve to improve priming

Net inlet pressure available too low Check NIPA, NIPR~, recalculatesystem. Change inlet system as needed.

On "Vacuum'' inlet system: On Install check valve in discharge line initial start-up, atmospheric "blowback'' prevents pump fromdeveloping enough differentialpressure to start flow.

No flow Relief valve not properly adjusted, Adjust or clear valveor held off seat by foreign material(flow is being recirculated to inlet)

Insufficient flow Speed too low to obtain Check flow-speed curvedesired flow

Air leak due to bad seals or Replace seals, check inlet fittings.pipe connections

Fluid vaporization Strainers, foot valves, inlet fittings Clear lines. If problem continues,("starved'' pump inlet) or lines clogged inlet system may require change

Inlet line size too small, inlet line Increase inlet line size. Reduce length,too long. Too many fittings minimize direction and size changes,or valves. Foot valve, strainers reduce number of fittings.too small .

NIPA too low Raise liquid level in source tank

NIPA too low Increase by raising or pressurizingsource tank

NIPA - Net Inlet Pressure Available at PumpNIPR - Net Inlet Pressure Required by Pump

TROUBLESHOOTING

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Fluid vaporization NIPA too Low Select larger pump size with(''starved'' pump inlet) smaller NIPR

Fluid viscosity greater Reduce pump speed and acceptthan expected lower flow, or change system to

reduce line losses.

Fluid temperature higher than Reduce temperature, reduce speed expected (vapor pressure higher) and accept lower flow or change

system to increase NIPA

Insufficient flow. Fluid Relief valve not adjusted Adjust or clearbeing bypassed or jammedsomewhere

Flow diverted in branch line, open Check system and controlsvalve, etc.

Insufficient flow. Hot (HC) or extra clearance rotors Replace with standard clearanceHigh slip on '"cold'' fluid, and/or low rotors

viscosity fluid

Worn pump Increase pump speed (within limits).Replace rotors, recondition pump.

High pressure Reduce pressure by system changes

Noisy operation Cavitation

High fluid viscosity, Slow down pump, reduceHigh vapor pressure fluids, temperature, change systemHigh temperature

NIPA less than NIPR To increase NIPA or reduce NIPR, see Engineering Manual

Air or gas in fluid

Leaks in pump or piping Correct leaks

Dissolved gas or naturally Minimize discharge pressure. Also aerated products see "Cavitation'' above.

•Mechanical noisesRotor to body contact

Improper assembly Check clearance with shims.See page 34 and 35.

TROUBLESHOOTING

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TROUBLESHOOTINGProblem Probable Causes Solutions

Noisy operation • Rotor to body contactDistortion of pump due to Reassemble pump or re-installimproper piping installation. piping to assure free running

Pressure higher than rated Reduce pressure if possible

Worn bearing Rebuild with new bearings.Lubricate regularly

Worn gears Rebuild with new gears. Lubricate regularly

Rotor to rotor contact

Loose or mis-timed gears. twisted Rebuild with new partsshaft, sheared keys. worn splines

• Relief valve chattering Re-adjust, repair or replace

• Drive component noise-gear Repair or replace drive train trains, chains, couplings, bearings.

Pump requires • Higher viscous losses than If within pump rating, increase driveexcessive power expected size(overheats, stalls.high current draw,breakers trip)

• Higher pressure than Reduce pump speed, increase expected line sizes

• Fluid characteristics

Fluid colder than expected. Heat fluid. insulate or heat traceviscosity high lines. Use pump with more running

clearances.

Fluid sets up in line and pump Insulate or heat trace line.during shut down Install "soft start" drive.

Install recirculating bypass system.Flush with other fluid.

Fluid builds up on pump surfaces Use pump with more running(example. latex, chocolate. clearancefondants)

''Short'' pump High corrosion rate Upgrade material of pumpservice life

Pumping abrasives Larger pumps at slower speeds,can help

Speeds and pressures higher Reduce speeds and pressures bythan rated changes in system

Worn bearings and gears due to Set up and follow regularlack of lubrication lubrication schedule

Misalignment of drive and piping. Check alignment of piping. CheckExcessive overhung load or drive alignment and loads. (Page 9)misaligned couplings.

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OILISO Grade 320, SAE 140 or AGMA Number 6EP

GREASENLGI Grade No. 2, EP, Lithium-based lubricant is standard

DRIVE LUBRICATIONRefer to drive manufacturer's manual shipped withunit.

*OIL CAPACITY (GEARS)SHAFT

MODEL TOP OR SIDEBOTTOM MOUNT

5040 2 oz. (60 ml) 4 oz. (120 ml)5050 6 oz. (170 ml) 9.5 oz. (280 ml)5060 6 oz. (170 ml) 9.5 oz. (280 ml)5070 11 oz.(320 ml) 20 oz.(600 ml)5080 17 oz. (500 ml) 44 oz. (1300 ml)

CLEANING

SECTION VOPERATION

NOTE: All hot clearance rotors are identified withan etched letter "H" on rotor hub.

OIL LEVEL

CLEANOUTPLUG

OIL FILL

OIL FILL

OIL LEVELOILDRAIN

TOP SHAFT DRIVE

OIL FILLBOTTOM SHAFT DRIVE

OIL LEVEL

BEARING GREASEFITTINGS (4)

FRONT

MOUNTING POSITIONS

A

B

(Left hand or right hand shaftas viewed from the front)C SIDEMOUNT DRIVE

*Oil Capacities are shown for reference. Fill oil to oillevel line.

The Waukesha pump is designed to be completely disassembled for thorough and easy cleaning .Clean the pump every day or at the end of a process. Disassemble the fluid head as outlined. Remove and clean the O-rings, sleeves and pump seals. Where possibility of material "setting up" during shut down exists, flushing with solvent or disassembly of fluid head and manual cleaning are required.

The Ductile Iron Pump should be coated with a rust preventative during extended shutdown periods and prior to storage.

Normal operation covers a speed range of 0-600 RPM and pressure range of 0-200 PSI. Temperaturerange with standard rotors is -40° to 200° F. and with hot clearance rotors, 180° to 300° F. (For operationat higher temperatures, consult SPX FLOW.)

See START-UP CHECK LIST (Page 10) and TROUBLESHOOTING (Page 11-14) for additional operationinformation.

LUBRICATIONThe gears are factory lubricated withISO Grade 320 oil at the quantityshown for top or bottom shaft mounts. Ifyou mount your pump other than top orbottom shaft drive, check oil level.

The bearings are factory greased with NLGI Grade No. 2, EP.

Change oil every 750 hours. If pump is installedwhere moisture and condensation are heavy,change oil more frequently.

Bearings must be greased every 750 hours or lessdepending on moisture and condensation condi-tions. Excess grease will accumulate in the gearcase and can be removed through the cleanouthole covered with plastic plug.

NOTE: For hot or cold extremes use appropriatelubricant as shown in the following tables.

12-18-15

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The following routine “look-feel” checks are to bemade by the system operator during shut-downperiods.

WARNINGDisconnect power from pump drive before removing cover.

VISUAL CHECKSCHECK ROTOR TIPS FOR WEAR AND CLEAR-ANCERemoval required: Cover, Rotors; see pages 21-221. Indications of metal-to-metal contact betweenrotor wings means the pump should be repairedor replaced.

CHECK ROTOR SPLINES FOR WEAR Cause Corrective MeasureWorn shaft spline .... Replace shaft.Worn rotor spline .... Replace rotor.

NOTE: Usually both parts will wear. The usualcause is a rotor which has been loose for extendedrunning periods.

CHECK ROTOR HUB END for signs of wear. (Endlocks against the shaft shoulder.) Cause Corrective MeasureExtended runningwith loose rotorretainingbolts .................. Replace rotor or reshim shaft to

maintain back face clearance.See Table 1 (Page 35) andSection IX, (Page 26)

SECTION VlMAINTENANCE

GENERAL

In the maintenance of pumps it is important to recognize when parts are wearing excessively.Detecting wear in the early stages will let you repair your pump at minimum cost and get it backinto operation at the earliest date.

Periodic cleaning and a simple “look-feel” inspection of your pump are recommended as goodoperating procedures and as a means of detecting signs of trouble at an early stage. They requireonly a few minutes and may save you an appreciable amount of money.

A more detailed maintenance inspection should be scheduled annually. See ANNUALMAINTENANCE, Page 20.

CLEARANCE BOTH SIDESMUST BE EQUAL

SPLINE

SPLINE

AREA OFWEAR

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SHOULDER

KEYWAY

SHAFT

KEY

NUT

30 LB.

30 LB.

3. CHECK SHAFT SHOULDER for deterioration.(Rotor hub locates against.)Cause Corrective MeasureLoose rotor shaft........... Reshim or replace

to maintain correct running clearances.(See table 1, Page 35)

Loose gears.................. Remove gear andinspect key, keyway and shaft. If all are in good condition, re-assemble and retighten gear retaining nuts to specified torque. (See Table 2. Page 35)

Worn gears...................... Replace gears.Twisted shaft ................. Replace shaft.

"FEEL" CHECKSGEAR/BEARING CHECKRemoval required: Gearcase oil,gear cover, gears. Page 31

1. Gear Back Lash - If there is any free movement when rotating either shaft without transmitting motion to other shaft, the back lash is excessive. Cause Corrective MeasureWorn gear teeth.............. Replace gear.Gear loose on shaft ........ Remove gear and

inspect key, keyway and shaft. If all are in good condition, re-assemble and re-tighten gear retaining nuts to specified torque. (See Table 2. Page 35)

NOTE: Replace oil seal in cover when assembling.

CHECK BEARING CONDITIONRemoval required; Fluid Head Assembly and Seals

Pages 21-222. Bearing Condition - If movement of either shaftcan be detected when hand loading the rotor endof the shaft (approximately 30 Ibs. force appliedas illustrated), bearing may be failing.Cause Correctlve MeasureLack of lubricant orhigh overload................ Replace bearings and

review lubrication schedule. (Page 15) Check for means to reduce hydraulic loads.

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SEAL MAINTENANCE1. Packing Seal

a. To suit the required service, a variety ofpacking materials and replaceable shaftsleeves are available. Standard packingmaterial is braided teflon-compounds.Standard sleeves are 316 stainless; optionalsleeves of ceramic coated stainless areavailable.

b. External adjustment with gland nuts willmaintain sealing until worn packing can beconveniently replaced.

c. New packing ring can be installed byloosening gland, sliding it back and insert-ing packing into the cavity in front of gland.

d. DO NOT TIGHTEN GLAND EXCESSIVELY.A small amount of liquid leakage is normal for packing lubrication.

c. Remove packing retainers with a screwdriver.

d. Turn body over, remove gland and use adowel and soft hammer to drive packing ringsfrom body.

Packing Replacementa. To facilitate repacking, disassemble the fluid head

assembly from bearing gear case.(See Section Vlll, page 21)

b. Clean and inspect shaft sleeves; if worn, removeand replace both sleeve and shaft O-ring.

REMOVABLE SLEEVE

SHAFT O-RING

STOP PIN

GLANDNUT

PACKING

SLEEVE

DOWEL

PACKINGRINGS

FLUID HEADASSEMBLY

LIFT& PULL TAB

NOTE: Seat Retainer may also be called gland.

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e. Refer to parts list and drawing for your pump. As-semble packing components into body cavity as shown in the drawing. Stagger the end joints in the packing rings so they do not line up. Snug up gland but DO NOT tighten.

f. Make final adjustment of packing glands after startup.

2. Mechanical SealsA copy of seal manufacturer's descriptive literature is sent with your pump for service and parts identification . Shut off power and close isolation valves.

BODY

CRITICALDIMENSION

GLAND

Critical dimension is set at factory and is unique to each different type of seal used. Measure and record before removing from shaft.

Inside Seal

a. If seal is leaking, replacement is recommended.

b. To replace seal and seal seat, the fluid head must be removed. See Section IX for proper procedure. (Page 26)

NOTE: The pump can be repacked without removing fluid head if proper tools and expertise are available. See pictures for helpful hints.

CRITICALDIMENSION

ALL STANDARD SEALS ARE SHOWN ON PAGES 51-55

SEAT RETAINER (GLAND)

STOP PIN

WARNINGWhen working with hazardous fluids it is recommended the pumping head be drained and flushed before disengaging seal faces.

Outside Seal a. Flush off any scale or crusted product that may

have accumulated around the shaft, seal face and seal springs.

b. Check to see if seal is tight against seat. Reposi-tioning seal to increase face seating pressure is suggested.

c. Check for cracked or damaged seal face by re-

moving seal seat retainer bolts and sliding retain-er back to expose sealing faces. If no faults are visible and leak persists or damaged is found, the replacement of seal and seal seat is recommend-ed. To replace seal and seat, the head must be removed. See Section VIII for proper procedure. (Page 21-22)

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Dual Inside and Outside Seal a. Turn on seal water.

b. If water leaks past the outside seal, flush off any scale or crusted product that may have accumulated around the shaft and seal area and seal springs.

c. Check to see if seal is tight against seat. Reposi-tioning seal to increase face seating pressure is suggested.

d. Check for cracked or damaged seal face by remov-ing seal seat retainer bolts and sliding retainer back to expose sealing faces. If no faults are visible and leak persists or if damaged face is found, the re-placement of seal and seal seat is recommended. To replace seal and seat, the fluid head must be removed. See Section VlII (Page 21) for proper procedure.

e. Remove pump cover and turn on seal water.

f. If water leaks past inside seal into pump body, replace entire seal assembly and seal seat. (See Section IX. Page 26) WARNING

Disconnect and lock out power from pump drive before performing maintenance.

The same general procedures and corrective measures outlined above should be performed and in addition the following preventive maintenance operations should be carried out at this annual checkout period.

1. Check bearing with a dial indicator for shaft radial play. If deflection is equal to or greater than rotor to body diametrical clearance (see Table 1, Page 35) replace bearings.

2. Remove gear cover and inspect gears for wear, back lash and looseness. Re-torque gear retaining nuts to proper torque. (See Table 2, Page 35)

3. Thoroughly inspect rotors for worn splines, bearing

shoulder wear, and stress cracks. Use dye check method to detect any fatigue type cracks at the stress points that may develop into serious trouble.

ROTORSTRESSPOINTS

ANNUAL MAINTENANCE

SEAT RETAINER (GLAND)

4. Review performance record on pump and check radial and back face clearances to determine wear and its effect on desired performance. (See Table 1, Page 35) and Section IX (Page 26). An adjust-ment on operating speed can compensate for wear in some applications. When wear and subsequent performance is objectionable, we suggest you take advantage of our reconditioning program. (See Section Vll Page 21)

CAUTION: If bearings or shafts are replaced in the field, extreme care should be exercised to position the shaft, by shimming, to maintain sufficient running clearances between the rotor wing faces and the pump body faces (backface and cover face). Refer to Table 1 (Page 35) and BACKFACE CLEARANCE, Section IX (Page 26). If rotors are slightly out of time, they can be re-timed by shimming the gears. It is important to hold the same back face dimen-sion for both rotors to avoid crossover interference.

2195-03012

TAPPEDHOLE

SECTION VllFACTORY RECONDITIONING

Waukesha Industrial pumps are designed so that they may be factory reconditioned twice and backedwith a new pump warranty each time.Factory reconditioning involves replacement of all worn parts such as shafts, bearings, oil seals, gears,etc. The pump body and cover are re-machined and new rotors are installed. The pumps are stampedR-1 or R-2, after the serial number, designating that they have been reconditioned once or twice.

NOTE: It is advisable to contact the factory and furnish the serial number of any pump being consideredfor reconditioning.

When pumps require reconditioning it is recommended that they be returned to Waukesha Cherry-Burrellwith proper purchase order. Where this is not practical, a "reconditioned" pump may be ordered inadvance of the actual return of the pump being replaced.While a large stock of reconditioned pumps is maintained, normal delivery of fourweeks should beanticipated. In these cases an invoice will be issued for the price of a new pump with credit allowedupon receipt of the old pump at the factory so that net cost will be that of a reconditioned pump.

INTERCHANGEABILITY

All new pumps are identified by a serial number on bearing gear case nameplate and stamped on topof pump body. The gear case and body must be kept together as a unit because of back face clearance.The rotors, seals and covers can be interchanged between units.

ALL reconditioned pump parts must be kept together as a unit. These are specially machined and arenot interchangeable.

CAUTION: If new body is replaced in the field, it is most important to check back face and front faceclearances (See Table 1, Page 35). Re-shim shafts if required to avoid rotor and cover contact. Bothrotors must have the same clearance to avoid crossover interference.

SECTION VIIIDISASSEMBLY PROCEDURES

(Refer to Section X (Page 35) for parts identification, drawings, and tables)

WARNINGDisconnect and lock out all

power from pump drive beforeperforming service.

FLUID HEAD DISASSEMBLY

1. Remove eight cap screws from cover. Usetwo as jack boIts in tapped holes on top andbottom of cover and turn in evenly to push coveroff dowels and rotor hubs. Be sure to haveadequate support when sliding cover free,especially on the larger units.

REMOVE COVER

22 95-03012

a. To remove rotor retainer bolts, straighten lockclip tabs using a screw driver or drift. Then,when clear, use a conventional wrench and asharp counterclockwise impact to loosen bolt.Remove the rotor which has both wings ex-posed first.

CAUTIONSome mechanical seal models use the backside of rotor as a spring retainer and will, ifnot restrained. push rotor off shaft withpossible damage to rotor.

b. If rotor can not be removed by hand, use moreforceful means such as, A standard gear pullerused in the conventional manner, or a piece ofhard wood used as a lever between back of rotorhub and body. (Do not use metal bar, etc.)

2. Remove O-ring from cover groove and inspect.Discard if not in good condition.

3. Turn shaft to orient rotors as shown for easyremoval one at a time.

DRESS WITH FILE

4. Remove the second rotor in the same way.

REMOVE BODYBody with Packing Seal1. Remove packing gland nuts.

2. Remove body socket head retaining bolts. Usinga block against the base of the ports, tap the block,alternating sides, to drive the fluid head off of thelocating dowel pins, and slide body off shaft.

3. See SEAL MAINTENANCE, Section Vl, (Page 18)for disassembly procedure of packing.

SEAL

Body with Mechanical Seals1. Remove cap screws from seal seat retainers andslide retainers back against bearing gear case.

2. Loosen body retaining bolts and tap body withsoft hammer to drive body loose from bearing gearcase and dowel pins. Remove retaining bolts andslide body off shafts.3. Thoroughly clean the shafts. Dress off shaftaround shoulder against which rotor bottoms toremove "flared end" to aid in seal removal.

4. Loosen both inboard seals and slide off shafts.Then remove the seal seat and gaskets.

5. If equipped with outside seal, loosen set screws and slide off shafts.

6. Dress off burrs on shaft which resulted from seating of set screws with a file or emery cloth.

APPLY GEARPULLER HERE

TAB

TAB

REMOVE ROTORS

SEAL RETAINERBODYBOLT

2395-03012

REMOVE SHAFTS, BEARINGS ANDGEARS - ALL MODELS

CAP SCREW

GEAR CASE

SILICONE SEALANT

OIL SEAL

OIL DRAIN PLUG

GEAR CASECOVER

1. Remove oil drain plug and drain oil.

2. Remove cap screws from gear case cover.

3. Pull cover off shaft extension. If cover sticks, use soft hammer to loosen it.

4. Scrape silicone sealant from gear case and cover.

5. Remove oil seal from cover with an arbor press and discard.

6. Straighten locking tab of lockwashers.

LOCKWASHER

LOCKWASHER

24 95-03012

SHAFT REMOVAL

7. Prevent shafts from turning by wedging awooden block between the gears.

8. Use spanner wrench or drift to remove gear locknuts. Gears will be removed later.See step 10below.

NOTE: Protect liquid end of shafts by wrappingthem with tape.

9. Remove front bearing retainer bolts and pull offretainers. Scrape silicone sealant from retainer andcase. (If retainer is stuck, leave it in place; it willpress out when shaft is removed.)

RETAINER TAPE

LIQUIDEND

SILICONESEALANT

SHAFT

WOODBLOCK

RETAINER CAPSCREW

TAPE

TIMING GEAR

SPACER

10. Place gear case on an arbor press with liquidend down. Protect shaft ends with wood or plasticblock and press shafts out of gear case. Removetiming gears and spacers from drive end. (See Table 4 on Page 35 for hydraulic presstonnage required..)

GEARLOCK NUTS

BLOCK TO PREVENT SHAFT DAMAGE

2595-03012

REARBEARING

V-BLOCK

FRONTBEARING

REARGREASESEAL

BEARING RE-TAINER

BEARINGSPACER

V-BLOCK

11. Scrape silicone sealant; press out and discardgrease seal from front bearing retainers.

12. Remove shims. If they are to be re-used,identify them with the shaft on which they wereused.

13. Press out and discard both rear grease seals ingear case.

3. Secure shaft assembly in a soft jawed vise asshown. Open tab in lock washer. Remove frontbearing lock nut using a spanner wrench or driftpunch.

4. Remove front bearings using V-blocks and ahydraulic press. (See Table 4 on Page 35.)

5. Clean and inspect all parts thoroughly if they areto be re-used.

ALL MODELS EXCEPT 5080

1. Use hydraulic press and V-blocks to removebearings and spacer. (See Table 4 on Page 35.)

MODEL 5080

2. Remove rear bearing by using V-blocks and ahydraulic press. (See Table 4 on Page 35.)

SHIM

SILICONESEALANT

GREASESEAL

LOCK NUT

V-BLOCKS

BEARING

26 95-03012

GREASE

MODEL 5040Shaft Assembly1. Front Bearing Assembly

a. Coat front bearing area of shaft with grease. Place upright in hydraulic press with splineend down.

c. Place front bearing over shaft with shield side up.Press onto shaft until seated against shaft shoul-der. (See Table 4 on Page 35.)

b. Unwrap front bearing assembly.

SHIELD

FRONTBEARING

PRESS AGAINST INNER RACEONLY

PRESS AGAINSTINNER RACE ONLY

f. Slip rear bearing over shaft with shield side down.Press bearing onto shaft until it seats againstspacer and front bearing.

d. Place spacer over shaft onto bearing.

e. Coat shaft rear bearing area with grease.

REARBEARING

SPACER

SECTION IXASSEMBLY PROCEDURES

2795-03012

GREASE

SPACER

CUP

RADIUS

CONEAND ROLLER

SPACER

CUP

LOCK NUT

LOCK WASHER

SPACER

b. Unwrap front bearing assembly. Do not inter-change parts of one bearing assembly with an-other. These parts are precisely matched in manu-facture and must be installed as a matched assem-bly.

g. Apply grease to threaded areaon shaft and face of lock nut.

h. Install spacer, lock washer and lock nut. Finger-tighten nut.

MODEL 5050, 5060, 5070 AND 5080

Shaft Assembly

1. Front Bearing Assembly

a. Coat front bearing area of shaft with grease.Place upright in hydraulic press withspline end down.

CONE AND ROLLER

CONE AND ROLLER

MODEL 5080SHOWN

c. Lift cone and roller assembly out of bearingstack and place on shaft with radius down asshown. Press onto shaft until seated against shaftshoulder.

(See Table 4 on Page 35.)

d. Place spacer over shaft onto bearing cone.

e. Place bearing cup over cone and roller assem-bly, keeping the cup oriented with proper rollerassembly.

f. Coat remaining bearing cone and roller insidediameter with grease and slip them over theshaft with roller radius up. Press onto shaftand into cup to complete assembly of front bearingon shaft.

5080 ONLY

5080 ONLY

28 95-03012

MODEL 5080 only

CONE AND ROLLER

CONE AND ROLLER

i. Clamp shaft behind lock nut in a soft jawed vise anddrive lock nut tight using a spanner wrench or drift.(See Table 2 on Page 35 for torque requirements).

SPACERSCUP

CUP

5080

GREASERETAINER

SPACER

BEARINGSPACERb. Place shaft upright in an arbor press with gear end

up. Install bearing spacer on all model shafts.

NOTE: On 5080 only, install spacer and grease retainer with flange up.

c. Coat shaft bearing area with grease. Press bearing cone and roller assembly (with radius down) onto shaft. (For hydraulic press tonnage required, see Table 4 on Page 35)

5080Press cone and roller assembly until it seats against grease retainer and spacer.

CONE AND ROLLER

5080 ONLY

j. Bend lock washer tab into groove on nut to secureassembly.

MODEL 5040,5050,5060,5070 and 5080

2. Rear Bearing Assembly

a. Unwrap rear bearing assembly. Do not inter-change parts of one bearing assembly with another.These parts are precisely matched in manufactureand must be installed as a matched assembly.

d. Apply grease again. Slip bearing cup over rollerassembly. Install both inner and outer spacers.Place remaining cup onto outer spacer and press onthe remaining cone and roller assembly. (See Table4 on Page 35.)Be sure outer spacer is concentric on shaft.

Gear Case Assembly

1. Shaft InstallatlonFront Bearing Grease Seals-5080 only

a. Place bearing gear case on arbor press. Install front bearing grease seals, with lip towards center of cavity, flush with back face of bore.

b. Coat lip seals with grease.

ROLLER

CUP

SPACERS

CUPROLLER

5080 ONLY

Shims - ALL MODELS

c. To determine the shim thickness required for the front bearing, measure dimension "A" in the gear case and dimension "B" on the shaft to three decimal places (1.000, for example).

Using these values to calculate the shim thickness as follows:

Dimension "A" minus dimension "B" = required shim thickness.

d. Use standard shim packs to equal the required shim thickness. Place against shoulder in front bearing bore. (Also see Page 35.)

(SUGGESTED SHIMS)

FLUSH GREASE

GEAR CASE FRONT FACE

SHIM

RECONDITIONEDSHAFT

Model OLD SHAFT NEW SHAFT R1 R2.090 .090

INSTALL SHAFTSInstall shaft assemblies in gear case with spline end up and the drive shaft in proper location to give top or bottom drive as required. Press shafts into gear case until seated against shim pack.

95-03012 29

.116 - .120 .110ALL

12-18-201512-18-15

5080 ONLY

30 95-03012

j. Install grease seals in bearing retainers (lip in)and coat seal lips with grease.Coat retainer flanges with silicone sealant.

k.Install bearing retainers.

SHIM HERE IF REQUIRED

BEARING RETAINER

2. Rear Seal Assembly

a. Install spacer seals and gear spacers.

b. Coat lip of seals with grease.

c. Press in rear seals with lip facing out.

NOTE: Place plastic bag over shaft end to preventcutting seal when installing.

NOTE: Seal is flush with gear case on Model 5050,5060 and 5080 pumps. On the 5070 pump the sealwill protrude 1/8-inch out side of gear case surface.

e. Secure shaft assemblies in gear case withbearing retainers. No silicone sealant at this time.

NOTE: Retainer must seat firmly against bearingand leave .010"-.050" clearance with gear case.Use shims between bearing and retainer if re-quired.

g. Check back face clearance. See Table 4 onPage 35 and BACK FACE CLEARANCE, page 34.

h. Remove bearing retainers.

i. Grease front and rear bearing through greasefittings until grease is visible around ball assem-blies.

.010-.050"

SEAL (LIPFACES OUT)

SPACERSEAL

GEARSPACER

FRONT BEARING

BEARING RETAINER

SEALLIP IN

SILICONESEALANT

FILL WITHGREASE

3195-03012

TIMING GEAR AND GEAR COVER ASSEMBLY- ALL MODELS

1. Place keys into shaft key slots. Slide gear withsingle punch mark onto drive shaft.Slide gear with two punch marks onto the shortshaft with punch marks straddling single mark ofdrive gear.

NOTE: Rotors must be at right angles. Shim a gearout to obtain proper timing if necessary.

2. Secure shafts from turning with a wood blockwedged between gears or rotors.

3. Apply grease to threaded area onshafts and face of lock nuts.

4. Slip on lock washers and lock nuts. Tighten locknuts with a spanner wrench or drift. Bend lockingtab to secure. See Table 2 on Page 35 for propertorque limit.

OIL LEVEL

COVER

WOODBLOCK

SILICONE SEALANTCAP SCREW

OIL SEAL

LOCKWASHERTAB

5. Press new oil seal into gear cover with lip facingin.

6. Place silicone sealant on back of gear cover andmount cover assembly onto gear case. (Tape shaftend to prevent cutting seal on keyway.) Secure withcap screws.

7. Install oil drain plug. Fill gear case with oilto proper level. (See OPERATION onpage 15)

GEAR CASE

OIL FILL

DRAIN PLUG

32 95-03012

SEE ACTUALSEAL DRAWING


SEAL

FLUID HEAD ASSEMBLY

Mechanical Packing

1. Place O-rings into grooves on shafts then slipsleeves onto shafts with pin indexed into notch onshaft.

2. For parts identification and correct order ofassembly see packing parts list and sectional draw-ing in Section XII, starting on page 38.

3. Mount body (with packing material) onto shaftsand secure to bearing gear case with two sockethead cap screws.

4. Make final gland adjustment when pump is inservice.

Mechanical SealsNOTE: Handle all seal components with extremecare.

1. External Type

a. Place seal rotating member onto shaft with sealface out. Lock seal onto shaft at proper location.(See seal assembly drawing for correct locationdimension.)

b. Slip seal seat retainer, retainer gasket, seal seat,and seat gasket onto shaft in that order.

c. Mount body on bearing gear case with two sockethead screws being sure to insert gaskets and sealseats into cavities on back of body. Secure sealseats with retainers using cap screws. *Recorddimension prior to disassembly. Refer to page 19.

2. Internal Type

a. Slip seal seat retainers onto shafts followed bygasket, seal seat and seat gasket.

b. Slip seals with seal face towards bearing gearcase onto shafts and secure at proper location withset screws. (See seal assembly drawing for correctlocation dimension.)

c. Secure pump body to bearing gear case with twocap screws.

d. Slip seat gasket into body followed by seal seat.Install seat retainer and gasket and secure with capscrews. (See Torque Table 1 on Page 35.)

O-RING

SLEEVEPIN

SOCKET HEADCAP SCREWS(2)

O-RING

GLAND

SEAL PACKINGSEAT RETAINER

SEAL SEATGASKET

SLEEVE


GASKET

SEAL SEAT

SEAL

SEATRETAINER(GLAND)

3395-03012


TO FLUSHINGLINES

3. Double Seal with Flushing

a. Place outer seal rotating member onto shaftwith seal face toward fluid head. Lock seal ontoshaft at proper location. (See seal assemblydrawing for correct location dimension.)

b. Slip seal seat retainer, retainer gasket, sealseat, and seat gasket onto shaft in that order.

c. Slip inner seals with seal face towards bearinggear case onto shafts and secure at properlocation with set screws. (See seal assemblydrawing for correct location dimension.)

d. Mount body on bearing gear case with twosocket head screws being sure to insert gasketand seal seats into cavities on back of body.Secure seal seats with retainers using cap screws(refer to seal assembly drawing.)

e. Connect flushing lines after pump is installed.

4. Flushing Connections (1/8" NPT-F)

NOTE: Flushing media should be piped into lowerconnection of each shaft seal and discharged outupper connections. Both inlets and both outletsmay be manifolds to simplify piping. (Figure A)

Typical Flush Piping

NOTE: High pressure outside seal is required.

1. Flushing media is restricted on discharge sideof pump flushing glands. (Figure B)

2. Set flow rate of approximately 1/4 GPM formost applications. For high temperature applica-tions, increase flow.

Rotor and Cover Assembly

1. Install rotors onto shaft splines and secure withretainer washers, lock clips and retainer bolts.Lock bolts with locking clip tab. (Apply anti-seizecompound to bolts.)

2. Insert O-ring in cover groove.

3. Mount cover over rotor hubs and body dowells.Secure with 8 cap screws.(See page 36 for relief cover installation andadjustment.)

INLET

FIGURE B

INLET

FIGURE A

ROTOR

WASHER

LOCK CLIP

BOLT

O-RING

RETAINER GASKET


SEAT RETAINER

INNER SEAL

SEAL SEAT

OUTER SEAL

34 95-03012

NOTE: Back face clearance for, both rotors must be the same to avoid crossover interferencewith rotor hubs.

PROPER CLEARANCES1. All Waukesha pumps are designed with closerunning clearances and the back face clearance isestablished with shims during assembly. The shaftis positioned with shims behind the front bearingand locked into bearing gear case. The rotors lockagainst the shaft shoulder and the resultant clear-ance between body back face and rotor wing is theback face clearance. (See Table 1, Page 35, forSTANDARD CLEARANCES)

2. To check back face clearance, mount bodyonto bearing gear case and secure with retainingscrews. Assemble rotors and secure with retainerwashers and cap screws.Measure clearance between body back face androtor wing with feeler gauges. This can be done byinserting the feeler guage in between the rotorwings and bending the guage into position behindthe wing or inserting the guage into a side port andbehind the rotor wing.Check readings against recommended STANDARDback face clearance in Table 1, Page 35. Make noteof any corrections required and follow examples todetermine exact shim adjustment to make and avoidunnecessary disassembly and reassembly.

3. To make shim adjustments it is necessary todisassemble rotors and body and remove shafts.(See Section Vlll, FLUID HEAD DISASSEMBLY onpage 21.) Make required shim adjustment andreassemble. Recheck back face clearances. Be sureboth rotors have the same clearance to avoidcrossover interference.

TOO MUCH CLEARANCE (FIGURE B)(The rotor seat shoulder of the shaft is projectingpast the body surface.)Remove shims equal (or as close as possible) todifference between measured clearance and speci-fied back face clearance.

NOT ENOUGH CLEARANCE (FIGURE A) (The rotor seat shoulder of the shaft is below thebody surface.)To determine amount of shims to add, use a straightedge or a parallel bar and depth gauge and measurethe dimension between the shaft shoulder and theface of the pump body as illustrated. Add shimsequal (or as close as possible) to that dimension plusspecified back face clearance.

TOO MUCHCLEARANCE

NOT ENOUGHCLEARANCE

Object: The dimension between the shaft shoulder and the body must be zero for both shafts.

Figure A Figure B

AC

ROTOR

PUMP BODY

RETAINERCAP SCREW

B

A= BACK FACE CLEARANCEB=ROTOR TO BODY CLEARANCEC=FRONT FACE CLEARANCE

3595-03012

REC. SHAFT ORIGINAL NEW

MODEL SHAFT SHAFT R1 R2

5040 .116-.120 .110 .090 .0605050 .116-.120 .110 .090 .0605060 .116-.120 .110 .090 .0605070 .116-.120 .110 .090 .0605080 .120-.126 .110 .090 .060

TABLE 4. ARBOR OR HYDRAULIC PRESS REQ'D - TONS

FRONT REAR BEARING SHAFT BEARING SHAFT

MODEL IN OUT ON OFF ON OFF

5040 0.25 0.5 0.5 0.1 0.5 0.1

5050-5060 0.5 1 2 5 3 5

5070 0.5 1 5 15 5 15

5080 0.5 1 5 20 5 20

SECTION XREFERENCE TABLES AND REPAIR PARTS LIST

TABLE 2. TORQUE VALUES-FT-LBS

LOCK NUTSMODEL FRONT ROTOR BEARING GEAR RETAINER5040 - 100 305050 - 140 385060 - 140 385070 - 230 385080 360 320 38

TABLE 3. SUGGESTED SHIMS

5040

5050

5060

5070

5080

.002-.0025 .003-.004 .0025-.005

.002-.0025 .003-.004 .004-.006

.0025-.003 .0035-.005 .004-.006

.004-.005 .004-.0055 .004-.008

.005-.006 .005-.007 .005-.009

A B C BACK ROTOR FRONT

MODEL FACE TO BODY FACE

*For non-standard rotor clearance, contact ApplicationEngineering at Waukesha Cherry-Burrell

TABLE 1. STANDARD ROTOR CLEARANCES*

36 95-03012

1 7 12 5 2 3

*Bushings are shipped loose. Orient them with body dowelpins. Be sure VALVE mechanism is on DISCHARGE SIDE ofpump.

ADJUSTING SCREW(ITEM 2) ON DISCHARGESIDE.

P 11

6

8

4

9-10

020 002 001 050 002 001 200 022 001 300 022 001020 020 001 050 002 001 200 002 001 300 020 004000 060 002 000 060 001 000 060 001 000 060 001020 071 000 050 071 000 200 071 000 300 071 000020 073 000 050 073 000 200 073 000 300 073 00036-92 36-99 36-99 36-99000 076 003 000 076 002 000 076 005 000 076 00630-283 - - - - 30-349 - - - - 30-349 30-349N70222 N70041 N70232 N70235020 116 002 050 116 002 - -020 116 003 050 116 003 - -N70034 N70227 N70045 N70157020 176 000 050 176 000 200 176 000 200 176 000

ITEM QTY DESCRIPTION 5040 5050/5060 5070 5080Cover Assembly

1 1 Cover 316 SS2 1 Socket Head Cap Screw3 1 Adapter4 1 Piston5 1 Hex Jam Nut6 1 Spring, Relief Valve7 2 Hex Head Capscrew

46

8 1 O-Ring Buna - N9 * 1 Bushing SST1 0 * 1 Bushing SST1 1 1 O- Ring Buna - N1 2 1 Spring, Retainer Steel

PARTS LIST

2. Turn on pump.

a) Close discharge valve slowly and observegauge. Do NOT ALLOW PRESSURE toexceed 200 PSI.b) Turn adjusting screw clockwise.Observegauge. When desired relief pressure is observed,lock adjusting screw with locknut.c) Open discharge valve. Relief valve is setand will open if system pressure exceeds presetlimit.

Without pressure gauge in discharge Line.1. Turn adjusting screw clockwise and observeproduct flow at discharge of system.2. When product flow reaches maximum or desiredflow rate, lock adjusting screw with locknut.

Adjustable spring tension operated piston oppositethe pumped fluid. The pump cover is reversible forright or left hand flow direction. O-ring seals are fur-nished in materials compatible with the product be-ing pumped.

INSTALLATIONValve Mechanism MUST BE ON DISCHARGESIDE.

ADJUSTMENT:With pressure gauge and valve in dischargeline.1. Turn adjusting screw counterclockwise until lossof spring pressure is felt. then turn clockwise untillight spring pressure is resumed.

FOR INDUSTRIAL STAINLESS STEEL("I")AND DUCTILE IRON ("Dl") PUMPMODELS 5040, 5050, 5060, 5070, and 5080

WAUKESHA INTERNAL BY-PASS RELIEF VALVESECTION XI

3795-03012

Pump ModelValve face area (sq. inches)Maximum valve travel (inches)Spring rate(lbs per 0.1 inch)Ref. spring part nurnber000-076-006Adjustment screw pitch( threads per inch)Amount of spring compression(No. of turns/inches)1 turn/ 0.1 inch2 turns / 0.2 inch3 turns / 0.3 inch4 turns / 0.4 inch5 turns / 0.5 inch6 turns / 0.6 inch7 turns / 0.7 inch8 turns / 0.8 inch9 turns / 0.9 inch10 turns / 1.0 inch11 turns / 1.1 inch

5050/50602.776

0.96

7 0

1 0

25 psi/0.86 in 50 psi/0.76 in 76 psi/0.66 in101 psi/0.56 in126 psi/0.46 in151 psi/0.36 in177 psi/0.26 in202 psi/0.16 in227 psi/0.06 insolid

5080 5.67 1.1

120

10

21 psi/1.0 inch 42 psi/0.9 inch 63 psi/0.8 inch 84 psi/0.7 inch105 psi/0.6 inch126 psi/0.5 inch147 psi/0.4 inch168 psi/0.3 inch189 psi/0.2 inch210 psi/0.1 inch

solid

Note: Spring force on valve increases as valve opens, and at the same rate as an equalamount of valve stem adjustment. For example, if the valve opens 0.2 inches, theincrease in spring load is the same as making two turns of the adjustment screw.

Relief Valve Data

Product cracking pressure/Remaining available travel (psi/inches

1 0

5070 4.43 0.9

120

50402.483

0.9 1

4 0

1 3

16 psi/0.83 in 32 psi/0.76 in 48 psi/0.68 in 64 psi/0.60 in 81 psi/0.53 in 96 psi/0.45 in113 psi/0.37 in129 psi/0.29 in145 psi/0.22 in161 psi/0.14 insolid

Product cracking pressure/Remaining available travel (psi/inches)

27 psi/.08 inch 54 psi/0.7 inch 81 psi/0.6 inch108 psi/0.5 inch135 psi/0.4 inch162 psi/0.3 inch185 psi/0.2 inch216 psi/0.1 inch solid

Pump ModelValve face area (sq. inches)Maximum valve travelinches)

Spring rate(lbs per 0.1 inch)Ref. spring part nurnber000-076-006Adjustment screw pitch( threads per inch )Amount of spring compression(No. of turns/inches 5040/inches 5050-60)1 turn / 0.08 in / 0.1 inch2 turns / 0.15 in / 0.2 inch3 turns / 0.23 in / 0.3 inch4 turns / 0.31 in / 0.4 inch5 turns / 0.38 in / 0.5 inch6 turns / 0.46 in / 0.6 inch7 turns / 0.54 in / 0.7 inch8 turns / 0.62 in / 0.8 inch9 turns / 0.69 in /0.9 inch10 turns / 0.77 inch11 turns / 0.85 inch

38 95-03012

5040

UN

IVER

SAL

IND

UST

RIA

L PU

MP

SECTION XIIUNIVERSAL INDUSTRIAL PARTS LIST 5040

2-17

-99

3995-03012

ITEM

PAR

T N

O.

DES

CR

IPTI

ON

QTY

5040

UN

IVER

SAL

IND

UST

RIA

L PU

MP

ITEM

PA

RT

NO

.

DES

CR

IPTI

ON

QTY

140

053

UI G

EA

RC

AS

E 0

40 M

AC

HIN

ED

1 1l

U 040 ,R

EV

OC

000 600 0402 3

000

142

300

SE

ALA

NT,

RTV

SIL

ICO

NE

BLU

E

A

S R

EQ

’D 4

30-2

83C

AP

SC

RE

W, H

EX

HD

5/1

6 18

X .7

56

500

0 03

0 01

3S

EA

L, S

HA

FT 1

.250

DIA

. X .2

50 W

D1

640

059

SHAF

T, D

RIV

E PA

CKI

NG

SEA

L1

4006

5S

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48 95-03012

ytQnoitpircseD.oN traPmetI71 0B1 114 FP0 SEAL JC #8B2 CARBON 272 025 014 012 SEAT, SEAL CERAMIC 5040 T STYLE 2

025 014 013 SEAT, SEAL, TUNGSTEN 2025 014 016 SEAT, SEAL, SILICON 2

2SS ,DNALG100 430 1B04776 025 042 001 GASKET, SEAT RING-OUTER 479 43-22 LOCK WASHER,1/4" 18-8 REG. 878 30-93 HHCS ,1/4-20 x 1.0" 18-8 8

ytQnoitpircseD.oN traPmetI29# CJ ,LAES000 411 1B007

72 025 014 012 SEAT, SEAL, CERAMIC 5040 T STYLE2025 014 013 SEAT, SEAL, TUNGSTEN 2025 014 016 SEAT, SEAL, SILICON 2

2SS ,DNALG100 430 1B04776 025 04 200 GASKET, SEAT RING-OUTER 479 43-22 LOCK WASHER, 1/4" 18-8 REG. 878 30-93 HHCS, 1/4-20 x 1.0" 18-8 8

ytQnoitpircseD.oN traPmetI29# CJ LAES000 411 1B007

71 0B1 114 FP0 SEAL JC #8B2 CARBON 273 025 014 027 SEAT, SEAL, FLUSH, CERAMIC 2

025 014 028 SEAT, SEAL, FLUSH, TUNGSTEN 2025 014 031 SEAT, SEAL, FLUSH, SILICON 2

2HSULF ,DNALG300 430 1B05776 025 042 001 GASKET, SEAT RING, OUTER77 V70147 O-RING-147 FDA VITON 279 43-22 LOCK WASHER, 1/4" 18-8 REG. 878 30-93 HHCS 1/4-20 x 1.0" 18-8 8

MECHANICAL PACKING (STANDARD SEAL PACKAGE)Item Part No. Description Qty63 STD 299 022 NUT 6100x2 464 87-699 TUBE-1 .187"x.030"W COPPER 2452 0B1 004 000 GLAND SS 250 0B1 033 000 PACKING 1055 0B1 033 100 PACKING SPACER 861 0B1 043 300 GASKET INSERT 254 0B1 047 000 LANTERN RING-GLASS FILLED 257 36-41 HEX NUT, 5/16-18 18-8 REG 460 0B1050 200 GLAND, INSERT 258 0B1 051 000 PACKING ,RETAINING RING 316SS 251 0B1 098 000 SLEEVE 279 43-22 LOCK WASHER,1/4" 18-8 REG 865 30-62 HHCS 1/4-20 x .50" 18-8 856 200 050 000 STUD-PACKING GL 459 40067 RETAINER-5040-RING 2.154 OD 253 N70024 O-RING, SHAFT, NITRILE BUNA 2

INSIDE-OUTSIDE MECHANICAL SEAL

5040 PACKING AND SEALS

INSIDE MECHANICAL SEAL

OUTSIDE MECHANICAL SEAL

5-30-96

4995-03012

Item Part No. Description Qty22B8# CJ LAES800 411 1C017

72 055 014 012 SEAL SEAT-CERAMIC 2055 014 013 SEAT, SEAL, TUNGSTEN 2055 014 016 SEAT, SEAL, SILICON 2

74 0C1 034 001 GLAND, 55 & 125I, 316 24TEKSAG100 240 55067

tQnoitpircseD.oN traPmetI y29# CJ ,LAES000 411 1C007

72 055 014 012 SEAL, SEAT-CERAMIC 2055 014 013 SEAT, SEAL, TUNGSTEN 2055 014 016 SEAT, SEAL, SILICON 2

ytQnoitpircseD.oN traPmetI 43X0026 GNITTIF 300 992 DTS36 43X0016 GNITTIF320 992 DTS46

65 87-699 TUBE-1 .187"x.030" COPPER IN. 242DNALG000 400 1C0 25

67 43-22 LOCK WASHER, 1/4" 18-8 REG. 821GNIKCAP000 330 1C005

55 0C1 033 100 PACKING SPACER 82TRESNI TEKSAG003 340 1C016

66 30-62 HHCS 1/4-20 x .50" 18-8 8 54 0C1 047 000 RING, LANTERN GLASS FILLED 2

4REHSAW DNALG000 940 1C026 56 0C1 050 000 STUD, 3/8-16 .375D 1.87LG 4 57 36-45 HEX NUT, 3/8-16 18-8 REGULAR 4

2TRESNI DNALG002 050 1C006 58 0C1 051 000 PACKING, RET RING 316SS 2

2EVEELS000 890 1C015 59 40068 RETAINER-5050-RING, 2.413OD 2 53 N70228 O-RING, NITRILE BUNA 2

MECHANICAL PACKING (STANDARD SEAL PACKAGE)




Item Part No. Description Qty29# CJ LAES000 411 1C00722B8# CJ LAES800 411 1C017

73 055 014 027 SEAL SEAT, FLUSH CERAMIC 2055 014 028 SEAL SEAT, FLUSH, TUNGSTEN 2055 014 031 SEAL SEAT, FLUSH, SILICON 2

2HSULF ,DNALG300 430 1C0574TEKSAG100 240 55067

77 V70152 O-RING-152 FDA VITON 278 43-22 LOCK WASHER, 1/4" 18-8 REG. 879 30-93 HHCS 1/4-20 x 1.0" 18-8 8


12-10-15

79 30-93 HHCS , 1/4-20 x 1.0" 18-8 878 43-22 LOCK WASHER 1/4" 18-8 REG. 8

74 0C1 034 001 GLAND, 55 & 125I, 316 24TEKSAG100 240 55067

LOCK WASHER 1/4" 18-8 REG. 878 43-2279 30-93 HHCS , 1/4-20 x 1.0" 18-8 8

50 95-03012

29# CJ ,LAES000 411 1C00722B8# CJ ,LAES800 411 1C017

73 055 014 027 SEAL SEAT, FLUSH CERAMIC 2055 014 028 SEAL SEAT,FLUSH TUNGSTEN 2055 014 031 SEAL SEAT, FLUSH SILICON 2

2HSULF ,DNALG300 430 1C0574TEKSAG100 240 55067

77 V70152 O-RING-152 FDA VITON 278 43-22 LOCK WASHER, 1/4" 18-8 REG. 879 30-93 HHCS 1/4-20 x 1.0" 18-8 8

22B8# CJ ,LAES800 411 1C01772 055 014 012 SEAL SEAT-CERAMIC 2

055 014 013 SEAL SEAT, TUNGSTEN CARBIDE 2055 014 016 SEAL SEAT, SILICON 2

74 0C1 034 001 GLAND, 55 & 125I, 316 24TEKSAG100 240 55067

43X0026 GNITTIF 300 992 DTS36 43X0016 GNITTIF320 992 DTS46

65 87-699 TUBE-1 .187"x.030" COPPER IN. 242DNALG000 400 1C0 25

67 43-22 LOCK WASHER, 1/4" 18-8 REG. 821GNIKCAP000 330 1C005

55 0C1 033 100 PACKING SPACER 82TRESNI TEKSAG003 340 1C016

66 30-62 HHCS, 1/4-20 x .50" 18-8 8 54 0E1 047 000 RING, LANTERN GLASS FILLED 2

4REHSAW DNALG000 940 1C026 56 0C1 050 000 STUD, 3/8-16 .375D 1.87LG 4 57 36-45 HEX NUT, 3/8-16 18-8 REGULAR 4

2TRESNI DNALG002 050 1C006 58 0C1 051 000 PACKING, RETAINING RING 316SS 2

2EVEELS000 890 1C015 OC1 098 001 SLEEVE, CERAMIC COATED 2

59 40068 RETAINER-5050-RING 2.413OD 2 53 N70228 O-RING, NITRILE BUNA 2

MECHANICAL PACKING (STANDARD SEAL PACKAGE)ytQnoitpircseD.oN traPmetI

ytQnoitpircseD.oN traPmetI







29# CJ ,LAES000 411 1C00772 055 014 012 SEAL SEAT, CERAMIC 2


76 0C1 034 001 GLAND, 55 & 125I, 316 24TEKSAG100 240 55097

78 43-2279 30-93 HHCS , 1/4-20 x 1.0" 18-8 8

12-10-15

LOCK WASHER 1/4" 18-8 REG. 8

78 43-2279 30-93 HHCS , 1/4-20 x 1.0" 18-8 8

LOCK WASHER 1/4" 18-8 REG. 8

5195-03012


Item Part No. Description Qty57 36-41 HEX NUT, 5/16-18 18-8 REG 461 000 299 032 FITTING, MALE BRASS 452 200 004 000 PACKING GLAND 255 200 032 000 PACKING SPACER 850 200 033 000 PACKING C-13 854 200 047 000 LANTERN RING, GLASS FILLED 256 200 050 000 STUD,PACKING GL 458 200 051 000 PACK, RETAINING RING 251 200 098 000 SLEEVE, STAINLESS 2

200 098 003 SLEEVE, CERAMIC COATED 260 200 317 000 TUBE, FLUSHING 5/16 STEEL 459 40069 RETAINER,5070-RING, 3.636OD 253 N70140 O-RING, SHAFT, NITRILE BUNA 2


Item Part No. Description Qty70 200 114 000 CRANE SEAL, #9 271 200 114 002 CRANE SEAL, 8B2 273 200 014 027 SEAL SEAT, FLUSH CERAMIC 2

200 014 028 SEAL SEAT, FLUSH TUNGSTEN 2055 014 031 SEAL SEAT, FLUSH, SILICON 2

75 200 034 001 GLAND, FLUSH 277 200 042 001 GASKET, INNER T-SEAT VITON 278 200 042 002 GASKET, OUTER 279 30-34 HHCS, 5/16-18 x 1.0" 880 43-15 LOCK WASHER,5/16 884 111577 SHAFT GUARD

52 95-03012

Item Part No. Description Qty56 0C1 050 000 STUD, 3/8-16 .375D 1.87LG 457 36-45 HEX NUT, 3/8-16 18-8 REG. 461 000 299 032 FITTING, MALE BRASS 460 200 317 000 TUBE, FLUSHING 5/16 STEEL 4" 452 300 004 000 PACKING GLAND 2

20-138 4.0" OD X 3.375 ID X 1/16" TEFLON 850 300 033 000 PACKING-C 13 8

300 047 000 LANTERN RING, GLASS FILL 2300 051 000 PACKING RETAINING RING 2300 098 000 SLEEVE, 3.250 OD X 3.003/.006 240070 RETAINER, 5080-RING 4.157 OD 2

53 N70149 O-RING, SHAFT, NITRILE, BUNA 2

Item Part No. Description Qty70 300 114 000 SEAL, #9 CRANE 271 300 114 002 SEAL, #8-B2 CRANE 272 300 014 012 SEAT SEAL, CERAMIC 2


73 300 014 027 SEAL SEAT, FLUSH CERAMIC 2300 014 028 SEAL SEAT, FLUSH TUNGSTEN 2300 014 031 SEAL SEAT, FLUSH, SILICON 2

74 300 034 000 GLAND 275 300 034 001 GLAND, FLUSHING 2

STD 128 500 PIPE PLUG 476 300 042 001 GASKET 477 300 042 001 GASKET, INNER T-SEAT VITON 278 300 042 002 GASKET, OUTER T-SEAT W/FLUSH 280 43-28 LOCK WASHER, 3/8" 18-8 REG 879 30-60 HHCS, 3/8-16 x 1.25" 18-8 881 STD 299 003 MALE CONNECTOR 482 STD 299 023 FITTING 483 87-699 TUBIN G, COPPER 4






6-5-95

95-03012 53

54 95-03012

LEFT SIDE

RIGHT SIDE

1

2

BOTTOM

TOP

Part Number 001 061002

Relative Sizes

APPLICATION INSTRUCTIONSApply to clean, dry surface. Remove backing; position inplace, lay cover sheet over and burnish. (Alternatemethod; Use soft rubber roller to press label in place).Apply all labels to be readable from front of pump

33-62

33-60

33-61

33-63

LABEL PLACEMENT

Effective Date:January 26, 1995

= 2 each•**Place label behind grease fittings (on right side)

PUMP 1 2MODEL 33-62 33-60 33-63

**5040 • •5050 • •5060 • •5070, 5080 • •

S PX FLOW, Inc.

611 Sugar Creek Road

Delavan, WI 53115

P: (262) 728-1900 or (800) 252-5200

F: (262) 728-4904 or (800) 252-5012

E: [email protected]

SPX FLOW, Inc. reserves the right to incorporate our latest design and mate-

rial changes without notice or obligation.

Design features, materials of construction and dimensional data, as described

in this bulletin, are provided for your information only and should not be relied

upon unless confirmed in writing.

Please contact your local sales representative for product availability in your

region. For more information visit www.spx.com.

The green “>” is a trademark of SPX FLOW, Inc.

ISSUED 12/2015

COPYRIGHT ©2015 SPX FLOW, Inc.

Universal 5000 Industrial SeriesROTARY POS ITIVE D I S PLACE M E NT

PU M P

Documents

Universal 5000 Industrial Series - Hayward Gordon · 6 95-03012 2. Good Piping Practice. All piping to the pump should be supported independently, to minimize the forces exerted on