disassembly/assembly manual r11 2x2 · 2019. 11. 6. · jet design completely eliminates the need...

Disassembly/Assembly Manual

R11 2x2

RJ-DA-3 11/19

ROTO-JET PUMP

DISASSEMBLY/ASSEMBLY

R11 2x2

Table of Contents

i

1. GENERAL .................................................................................................. 1

1.1. INTRODUCTION ............................................................................. 1

1.2. ROTO-JET PUMP DESIGN ............................................................ 1

1.3. PUMP IDENTIFICATION ................................................................ 2

2. DISASSEMBLY/ASSEMBLY ..................................................................... 2

2.1. GENERAL ....................................................................................... 2

2.2. RECOMMENDED TOOLS .............................................................. 3

2.3. DISASSEMBLY/ASSEMBLY STANDS ........................................... 5

2.3.1. Model R11 Dimensional Drawing ......................................... 6

2.4. R11 PUMP SECTION DRAWING ................................................... 7

2.4.1. Parts List - R11 Pump .......................................................... 8

2.5. SEAL OPTION DRAWING ............................................................ 11

2.6. SEAL REPLACEMENT PROCEDURE ......................................... 12

2.7. BEARING REPLACEMENT PROCEDURE: ................................. 14

2.8. STAINLESS STEEL MANIFOLD REPLACEMENT ....................... 21

2.9. MAJOR COMPONENT REPLACEMENT ..................................... 23

3. HYDROSTATIC PRESSURE TESTING .................................................. 24

3.1. Manifold ........................................................................................ 24

3.2. Rotor and Rotor Cover .................................................................. 25

ROTO-JET PUMP


R11 2x2

Table of Contents Continued

ii

4. ROTOR ASSEMBLY BALANCING .......................................................... 25

5. SHIMMING .............................................................................................. 27

6. PARTS ..................................................................................................... 28

6.1. SPARE PARTS LIST .................................................................... 28

6.2. MAINTENANCE SUPPLIES ......................................................... 28

6.3. ACCESSORIES ............................................................................ 28

6.4. ORDERING PARTS ...................................................................... 28

7. MAINTENANCE RECORD ...................................................................... 30

8. APPENDIX A ……………………………………………………………31

R11 2x2 1

ROTO-JET PUMP


Model R11

1. GENERAL

1.1. INTRODUCTION

This manual has been prepared to assist you in understanding the construction and the correct methods of disassembly and assembly for your new Roto-Jet pump. The Roto-Jet pump is the simplest and most reliable high pressure pumping device ever invented. The design, material and workmanship incorporated in the construction of Roto-Jet pumps makes them capable of giving long, trouble free service. The life and satisfactory service of any mechanical unit, however, is dependent upon correct application, proper installation, periodic inspection and careful maintenance. We urge you to read and follow all of the directions in this manual. If additional copies are required or other detailed instructions are needed, the information may be obtained upon request.

1.2. ROTO-JET PUMP DESIGN

The exclusive patented Roto-Jet pump has only two basic working parts...a rotating case and a stationary pick-up tube collector arm within the rotating case. The Roto-Jet design completely eliminates the need for packing glands, wear rings or multiple stages as used in conventional centrifugal pumps, and also eliminates the complex pistons, rods, valves and springs required in reciprocating pumps. The Roto-Jet operates in the following manner: Liquid enters the intake manifold and passes into the rotating case where centrifugal force increases the pressure of the liquid and at the same time its velocity is increased. The velocity of the liquid in the rotor is converted into additional pressure as it jets into the pick-up tube.

R11 2x2 2

1.3. PUMP IDENTIFICATION Roto-Jet pumps are designated by a series of letters and numbers, such as R11-S252. The first group, R11, is an indication of the basic mechanical configuration and the second group, S252, designates the pick-up tube size. The pump nameplate gives both the pump model designation and the pump serial number. Permanent records for this pump are kept by the serial number and it must therefore be used with all correspondence and spare parts orders. This will ensure replacement of components in the original materials of construction.

2. DISASSEMBLY/ASSEMBLY

2.1. GENERAL The following are recommended dismantling and assembly instructions for your Roto-Jet pump. We urge that the instructions be read thoroughly before attempting to dismantle the unit. The component parts must be handled with care during the dismantling and assembly process. The work area should be clean and be equipped with the required tools. Depending on the accessibility of the pump and the extent of the repair or inspection required, the pump can be dismantled in place on its foundation. However, to facilitate the disassembly procedure, it is recommended that the pump be removed from its foundation and placed securely into a position in which the pump shaft is facing downward and the manifold is facing upward. Roto-Jet pumps offers assembly stands for mounting the unit during disassembly and assembly.

R11 2x2 3

2.2. RECOMMENDED TOOLS

Item No. Description Qty Part No.

Complete Tool Kit (includes special & purchased tools) 1 0663149

Special Tool Kit (includes items under special tools) 1 0661985

SPECIAL TOOLS

2 Lock Nut Tool *** 1 0661862

3 Pick-Up Tube Guide *** 1 0660898

4 Rotor Assembly Alignment Rod 1 0661986

5 Rotor Bearing Nut Adaptor 1 0661972

6 Drive Bearing Nut Adaptor 1 0661973

7 Rotor Guide Pin 3 0661974

8 Manifold Guide Pin *** 2 0661975

9 Seal Installation Tool *** 1 060580624

10 Seal Puller *** 1 0661976

11 Seal Mating Ring Puller *** 1 0661977

12 Manifold Puller *** 1 060580638

13 Measuring Bar 1 060580635

14 Tool Box 1 060095050

15 Socket 1/4" Hex Bit x 1-1/2" Long x 3/8" Drive 1 060095032

*** Tool Requirement for Seal Replacement Only.

R11 2x2 4

2.2 RECOMMENDED TOOLS, Continued

Item No. Description Qty Part No.

PURCHASED TOOLS

16 Socket 5/16" Hex Bit x 3/8" Drive 1 060095060

17 Eyebolt With Nut 3/8-16 3 0661979

18 Tension Tester - V-Belt 1 060095057

19 Scriber 1 060095045

20 Temperature Stick 150° 1 060095047

21 Temperature Stick 175° 1 060095048

22 Bearing Heater (120V/60Hz) 1 060095046

23 Torque Wrench 5-80 ft-lbs. 1 060095026

24 Torque Wrench 30-250 ft.lbs. 1 060095027

25 Depth Micrometer - 0.3", 6" Base 1 060095051

26 Indicator, Test Dial .0005 1 060095053

27 Magnetic Base - Test Indicator 1 060095054

28 Bearing Separator - Spread 1/2" to 8-5/8" 1 060095022

29 Puller - 17.5 ton, 9-1/2" Reach 1 pair 060095023

30 Puller - 17.5 ton, 16-1/2" Reach 1 pair 060095025

31 Protector, Shaft (Puller) 1 060095037

2.2.1. Assembly Stands

Item No.

Description

Qty.

Part No.

1 Pump Assembly Stand Kit (Includes stand & swivel hoist ring)

1 060580652-K1

2 Rotor Assembly Stand 1 0665443-03

3 Ring, Swivel Hoist (D-Ring) 1 0667025

Assembly stand can be used for all Roto-Jet pumps.

R11 2x2 5

2.3. DISASSEMBLY/ASSEMBLY STANDS

CAUTION When lifting the pump

into the vertical position with or

without the assembly stand a swivel hoist ring shall be used in

place of the lifting eye bolt.

R11 2x2 6

2.3.1. Model R11 Dimensional Drawing

R11 2x2 7

2.4. R11 PUMP SECTION DRAWING

TORQUE TABLE

Item No.

Ft. Lbs.

N•m

81 217 294

15 48 65

7 47 64

8 13 18

46 130 176

47 166 225

57 4 5

58 35 27

94 48 98

60 35 98

97 47 64

R11 2x2 8

2.4.1. Parts List - R11 Pump

Item No.

Qty

Description

Part No.

Material

1 1 Pick-Up Tube S252 S338 S433 D433

0661429 0660332 0660333 0661010

17-4 PH 17-4 PH 17-4 PH 17-4 PH

81 1 Lock Nut Pick-Up Tube 0661541 316 SST

82 1 Key, Pick-Up Tube 0661624-001 316 SST

4 Seal Kit Consisting of: 06P661632-CT

49 1 O-Ring, Pick-Up Tube 0660373 Nitrile

75 1 Seal 0660472JC 316/Carbon

44 1 O-Ring, Seal 060083779 Nitrile

91 1 Retaining ring 060099130 SST

78 1 Seal Mating Ring 0652046-002 SST/TC

92 1 Drive Pin 0662519 S/S

69 1 O-Ring, Seal Mating Ring 060083625 Nitrile

93A 1 Seal Spacer (2) Steel Stainless Steel

0661552

0661552-1

Steel SST

93B 1 Flush Ring (2)

0661525 316 SST

13 1 Rotor Assembly - Stacked & Balanced Ductile Iron/Nitrile Stainless Steel/Nitrile

0663714-01 0663715-01

Consisting of:

6 1 O-Ring, Rotor 0660372 Nitrile

5 1 Drive Shaft (1) 0661535-001 Steel

22 2 Oil Ring 0661524 Steel

20 1 Oil Slinger, Drive End 0661522 Steel

19 1 Oil Slinger, Rotor End 0661523 Steel

21 1 Spacer 0661561 Steel

15 1 Endplate 0663542-1 DI

83 6 Capscrew, Driveshaft 0660337 Steel

3 1 Rotor (1) Ductile Iron Stainless Steel

0661458

0661458-002

DI

SST

4 1 Rotor Cover (1) Ductile Iron Stainless Steel

0661540

0661540-002

DI

SST

R11 2x2 9

2.4.1 Parts List - R11 Pump, Continued

Item No.

Qty

Description

Part No.

Material

7 12 Capscrew, Rotor Cover 0660335 Steel

8 2 Drain Plug, Rotor Cover Steel Stainless Steel

060068656 060068677

Steel/Nitrile SST/Nitrile

98 1 Lip Seal 0663720 Viton

26 Bearing Kit Consisting of: 0661950

* 85 1 Excluder, Internal 0661623 Nitrile

* 46 1 Radial Bearing Nut 0661555 Steel

* 52 1 O-Ring, Bearing Cap 0661819 Nitrile

* 13 1 Radial Bearing 0660346 Steel

* 23 1 Spacer Set 0661526 Steel

* 12 1 Thrust Bearing 0661549 Steel

* 47 1 Rotor Bearing Nut 0661556 Steel

* 11 1 Rotor Bearing 0660347 Steel

* 66 1 Wave Spring 0661580 Steel

* 56 1 O-ring, Endplate 0661888 Nitrile

* 84 1 Excluder, External 0662666 Nitrile

57 4 Capscrew, Pedestal Cover 060088325 Steel

18 1 Pedestal Cover 0663377 Steel

67 1 Breather Filter 0663057 Steel

58 4 Capscrew, Endplate 060088325 Steel

1 Eyebolt 0656866 Steel

17 1 Pedestal 0663711-1 DI

37 1 Nameplate 0660681 SST

65 4 Screw - Drive 060093116 SST

94 10 Capscrew, Manifold 060088352 Steel

36 1 Manifold Ductile Iron Stainless Steel

0661512

0662338-001

DI

SST

S/S Manifold Consisting of:

36 1 Manifold/Endbell 0663011-1 SST

95 1 Nozzle 0663012-1 SST

96 1 O-Ring 0662499-149 Viton

97 4 Capscrew, Nozzle 060088716 SST

* Bearing kit P/N 0661950 consists of the above noted parts.

R11 2x2 10

2.4.1 Parts List - R11 Pump, Continued

Item No.

Qty

Description

Part No.

Material

24 1 Plug, Flush Ductile Iron Stainless Steel

060067736 060067741

Steel SST

42 1 Plug, Manifold Ductile Iron Stainless Steel

060067738 060067748

Steel SST

43 1 Key, Drive Shaft 0614630-002 Steel

14 1 Bearing Cap 0661545 DI

38 AR Shims 0660383 Brass

60 4 Capscrew, Bearing Cap 060088815 Steel

68 1 Oil Sight Gauge 0660377 Steel/Acrylic

24 1 Plug, Oil Drain 060067736 Steel

84 1 Excluder, External (3) 0662666 Nitrile

34 1 Gasket, Cover 0662370 Nitrile

98 1 Lip Seal (4) 0663720 Viton

88 1 Roll Pin 0662665 Steel

NOTES:

(1) These parts, if purchased separately, require that the rotating assembly be balanced and pump be re-shimmed.

(2) Item 93A supplied in standard unit, item 93B supplied in pumps with seal

flush. (3) Item 84 is included in the bearing kit.

(4) Item 98 is included in the rotor assembly.

R11 2x2 11

2.5. SEAL OPTION DRAWING

Table 2.5 - Seal Option Parts

Item No.

Qty

Description

Part Number:

4 1 Seal Kit Carbon vs. T/C (standard) Seal Kit T/C vs. T/C

06P661632-CT 06P661632-TT

Components:

49 1 O-Ring - Pick-Up Tube 0660373

75 1 Seal - Pusher - Carbon Seal - Pusher - Tungsten Carbide

0660472-JC 060754067

44 1 O-Ring - Seal 060083779

91 1 Retaining Ring - Seal 060099130

78 1 Seal Mating Ring - Tungsten Carbide 0652046-002

92 1 Drive Pin - Seal Mating Ring 0662519

69 1 O-Ring - Seal Mating Ring 060083625

R11 2x2 12

2.6. SEAL REPLACEMENT PROCEDURE

The following instruction are applicable to seal replacement only with the pump being is a shaft horizontal position. Refer to figure 2.4 as well as section 6.0.

2.6.1. Recommended Parts

Seal kit.

2.6.2. Recommended Special Tools

Lock Nut puller Seal Puller Pick-Up Tube Guide Seal Mating Ring Puller Manifold Guide Pins Seal Installation Tool

2.6.3. Preparations for Disassembly

2.6.3.1. Lock out and tag the driver.

2.6.3.2. Blank off and drain the suction and discharge lines.

2.6.3.3. Disconnect and remove all piping from the manifold.

2.6.4. Cautions:

The following precautions are recommended to insure satisfactory operation of the pump after assembly.

2.6.4.1. Always replace any o-rings that are exposed during disassembly as

they can lose their seal integrity and may leak.

2.6.4.2. Be sure all parts are free from dirt, stray metal chips or any foreign matter and have been thoroughly cleaned.

2.6.4.3. All torque values assume lubrication with molybdenum disulfide on

threads and underside of capscrew heads. Refer to figure 2.4 for torque values.

2.6.4.4. When lifting the pump into the vertical position with or without the

use of the assembly stand a swivel hoist ring shall be used in place of the lifting eye bolt.

2.6.4.5. When tightening the swivel hoist ring provided with the assembly

stand kit (060580652-K1), torque to 100ft-lbs.

2.6.5. Disassembly:

2.6.5.1. Using the lock nut tool, unthread and remove the lock nut (81) which secures the pick-up tube (1) to the manifold (36). Note that this is a left-hand thread.

R11 2x2 13

2.6.5.2. Fully thread the pick-up tube guide into the pick-up tube (1). Tap lightly on the pick-up tube guide until the pick-up tube clears the o-ring (49).

2.6.5.3. Remove the ten hex head cap screws (94) which secure the

manifold (36) to the pedestal (17). Install two manifold guide pins into two threaded holes in the pedestal (17) at the two o'clock and ten o'clock positions.

2.6.5.4. Evenly thread two of the hex head cap screws (94) into the threaded

holes in the manifold (36) until the manifold moves free of the pedestal (17). Carefully guide the manifold over the pick-up tube until the pick-up tube guide is cleared. Place the manifold on a flat surface with the seal (75) visible.

2.6.5.5. Remove the seal retaining ring (91) from the manifold. Grasping the

inside diameter of the seal spacer (13a) or the flush ring (13b), pull to remove the seal (75) along with the seal spacer or the flush ring. If unable to remove by hand, remove using the seal puller.

2.6.5.6. Remove the pick-up tube o-ring (49) and the seal o-ring (44).

2.6.5.7. Place a rubber protective shield between the pick-up tube (1) and

the seal mating ring (78). Remove the key (82) from the pick-up tube.

2.6.5.8. Grasping the outside diameter of the seal mating ring (78), pull to

remove. If unable to remove by hand, install the seal mating ring puller and evenly thread the two capscrews against the rotor cover (4) until the seal mating ring is free of the rotor cover.

2.6.5.9. Remove the seal mating ring o-ring (69).

2.6.6. Assembly:

2.6.6.1. Lubricate and install the seal mating ring o-ring (69) in the rotor cover

(4). Lubricate the seal mating ring cavity with light oil.

2.6.6.2. Carefully guide the seal mating ring (78) over the pick-up tube guide and the pick-up tube (1). Align the hole in the seal mating ring with the driver pin (92) in the rotor cover (4). Slide the seal mating ring into place until flush against the rotor cover.

2.6.6.3. Lubricate and install the pick-up tube o-ring (49) and the seal o-ring

(44) in the manifold (65). Lubricate the seal cavity in the manifold with light oil. Place the seal spacer (13a) or the flush ring (13b) in the manifold cavity.

R11 2x2 14

2.6.6.4. Using the seal installation tool, insert the seal (75) into the manifold (36) cavity being careful not to damage the seal face. Install the retaining ring (91) into the manifold groove.

2.6.6.5. Clean seal face and the seal mating ring face. Remove protective

shield.

2.6.6.6. Being extremely careful not to damage seal or seal mating ring, install manifold (36). Slide pick-up tube guide through manifold. Align manifold on manifold guide pins and slide into place on pedestal while holding pick-up guide centered.

2.6.6.7. Remove the manifold guide pins and seat the manifold (36) into the

pedestal (17) by evenly torquing the ten hex head capscrews (94). Torque the capscrews to 72 ft. lbs. (98 N-M).

2.6.6.8. Using the pick-up tube guide, align the manifold (36) keyway and the

pick-up tube (1) keyway. Pull the pick-up tube past the o-ring (49) and against the manifold shoulder. Remove the pick-up tube guide.

2.6.6.9. Install the pick-up tube key (82) into the keyways. Using the lock nut

tool, thread lock nut (81) into pick-up tube. Torque lock nut to 217 ft. lbs. (294 N-M).

NOTE: The 1/2 inch seal drain on the manifold should not be

plugged.

2.6.6.10. This completes the seal replacement procedure. The pump may be put back into operation. Connect all piping and refer to Section 3.3 for start up procedures.

2.7. BEARING REPLACEMENT PROCEDURE:

WARNING: Before lifting the pump into the vertical position first remove the lifting eye and install the swivel hoist. When tightening the swivel hoist ring, torque to 100ft-lbs. Once the pump is re-assembled and in the horizontal position remove the swivel hoist and re-install the lifting eye. Reference APPENDIX A Drawing.


Seal Kit Bearing Kit Rotor Cover Plugs

2.7.2. Recommended Special Tools Lock Nut Tool Bearing Puller Pick-Up Tube Guide Bearing Heater Manifold Guide Pins Temperature Sticks Manifold Puller Rotor Guide Pins Seal Puller Bearing Nut Adapter Seal Mating Ring Puller Seal Installation Tool Eyebolt Rotor Alignment Rods

R11 2x2 15


2.7.3.1. Lock out and tag the driver.


2.7.3.3. Remove belt guard; slack off belt tension and remove belts; remove

pump sheave and key (43).

2.7.3.4. Drain, disconnect and remove all piping from the manifold.

2.7.3.5. Remove oil drain plug (24) and drain pedestal oil.

2.7.3.6. Drain rotor by removing the rotor drain plug (42) from the manifold (36). Rotate drive shaft (5) until the rotor cover drain plug (8) is visible through the unplugged hole in the manifold (36). Remove the rotor cover drain plug and rotate the drive shaft until the opening is at the bottom of the pedestal (17). Drainage will exit from the rotor drain under the pedestal.

2.7.4. Cautions

The following precautions are recommended to insure satisfactory pump operation after assembled.

2.7.4.1. Replace any o-rings that are exposed during the pump disassembly

process as they lose their seal integrity and may leak.

2.7.4.2. Be sure all parts are free of dirt, stray metal chips or any foreign matter and have been thoroughly cleaned.

2.7.4.3. All torque valves given assume lubrication with molybdenum

disulfide on threads and underside of capscrew heads. Refer to figure 2.4 for torque values.

2.7.4.4. When replacing pick-up tube, replace pick-up tube lock nut to avoid

attachment complication.

2.7.4.5. Always install new bearing nuts when replacing bearings. As they lose their positive locking capability when removed.

2.7.4.6. All three bearings should be replaced as a set.

2.7.4.7. To avoid creating an out of balance condition that makes the pump

susceptible to vibration damage, match mark capscrew and component relative positions for reassembly into same positions.

R11 2x2 16

2.7.4.8. Replacement of the rotor, rotor cover or drive shaft will require balancing of rotating assembly and shimming of pump. See section 2.9.

2.7.4.9. WARNING: When lifting the pump into the vertical position with or

without the use of the assembly stand a swivel hoist ring shall be used in place of the lifting eye. Reference APPENDIX A Drawing.

2.7.5. Disassembly

The following instructions are applicable to the pump being removed from the foundation and mounted in a position with the pump shaft facing downward and the manifold facing upward.

2.7.5.1. Using the lock nut tool, unthread and remove the lock nut (81) which

secures the pick-up tube (1) to the manifold (36). Note that this is a left handed thread.

2.7.5.2. Fully thread the pick-up tube guide into the pick-up tube (1). Lightly

tap on pick-up tube guide until the pick-up tube moves free of the o-ring (49).

2.7.5.3. Install the manifold puller in manifold (36) outlet. Remove the ten

hex head capscrews (94) which secure the manifold (36) to the pedestal (17).

2.7.5.4. Install the manifold guide pins and evenly thread two of the hex head

capscrews (94) into the threaded holes in the manifold over the pick-up tube until the pick-up tube guide is cleared. Remove the manifold puller ad place the manifold on a flat surface with seal (75) visible. Remove the manifold guide pins.

2.7.5.5. Place a protective shield between the pick-up tube and the seal

mating ring (78). Remove the key (82) from the pick-up tube keyway.

2.7.5.6. Remove the seal retaining ring (91) from the manifold (36). Grasping the inside diameter of the seal spacer (13a) or the flush ring (13b), pull to remove the seal (75) along with the seal spacer or the flush ring. If unable to remove by hand, remove using the seal puller.

2.7.5.7. Remove the pick-up tube o-ring (49) and the seal o-ring (44).

2.7.5.8. Remove the four hex head capscrews (58) which attach to the end

plate (15) to the pedestal (17).

2.7.5.9. Using the wrench flats, unthread and remove the breather filter (67).

R11 2x2 17

2.7.5.10. Remove the four hex head capscrews (57) which attach the pedestal cover (18) to the pedestal (17). Remove the pedestal cover. Remove gasket (34) from the pedestal.

2.7.5.11. Position the two oil rings (22) into the grooves of the rotor oil slinger

(19) and the oil slinger (20).

2.7.5.12. Thread the three eyebolts into three evenly spaced holes in the rotor cover (4). Adjust the eyebolt nuts until flush against the rotor cover.

2.7.5.13. Using a sling, lift and guide the rotor cover (3), the driveshaft (5) and

the bearings out of the pedestal (17). Being careful not to damage rotor cover hub, place the assembly on a flat surface or mount with rotor cover upward.

2.7.5.14. Match mark the location of each of the twelve socket head cap

screws (7) which secure the rotor cover (4) to the rotor (3).

2.7.5.15. Remove the twelve socket head capscrews (7) and install the rotor guide pins. Evenly thread three of the socket head capscrews (7) into the threaded holes in the rotor cover until the rotor cover is released from the rotor. Replace the three capscrews with three eyebolts.

2.7.5.16. Holding the pick-up tube (1) centered in the rotor cover (4), lift the

rotor cover.

2.7.5.17. Guide the pick-up tube out of the rotor cover. Place the rotor cover on a flat surface with the seal mating ring visible. Remove the rotor guide pin.

2.7.5.18. Grasping the outside diameter of the seal mating ring (78), pull to

remove from the rotor cover (4). If unable to remove by hand, install the seal mating ring puller and evenly thread the two capscrews against the rotor cover until the seal mating ring is free of the rotor cover.

2.7.5.19. Remove the seal mating ring o-ring (69) and rotor o-ring (12).

2.7.5.20. Being careful not to damage rotor lip, position assembly with shaft

up and vertical.

2.7.5.21. Remove the excluder (85). Using the bearing nut adaptor, remove the bearing nut (46) and put to the side to be used during bearing assembly. Remove the outer race of the radial bearing (13) and the outer ring of the spacer set (23).

R11 2x2 18

2.7.5.22. Install the bearing puller under the oil slinger (20). Adjust the bearing puller until the thrust bearing is free of the drive shaft (5). Remove the inner race of the radial bearing (13), inner ring of spacer set (23), thrust bearing (12), oil slinger (20), and the oil rings (22).

2.7.5.23. Using rotor bearing nut adaptor, remove the rotor bearing nut (47).

Do not reuse.

2.7.5.24. Install the bearing puller under the spacer (21). Adjust the bearing puller until the bearing (11) is free of the drive shaft.

2.7.5.25. Remove the rotor oil slinger (19), oil ring (22), rotor bearing (11),

wave spring (66), spacer (21), and endplate (15). Remove endplate o-ring (56) from endplate.

This completes the normal disassembly of the pump. If the rotor cover or the drive shaft are found to need replacement, refer to section 5.4 for further instruction.

2.7.6. Assembly

After the parts have been cleaned and inspected, the following procedure of assembly requires that the pedestal be mounted vertically as during disassembly.

2.7.6.1. Install with enter edge of lip seal (98) facing down into the endplate

(15). Lubricate and install the endplate o-ring (56), in the endplate groove. Place the endplate, the wave spring (66) and spacer (21) into position on the driveshaft (5).

2.7.6.2. Heat the rotor bearing (11) to 160°-180° F (71°-82° C). Quickly slide

the rotor bearing onto the driveshaft (5) and against the spacer (21).

2.7.6.3. Install the rotor oil slinger (19) and the rotor bearing nut (47) on the driveshaft. Using the rotor bearing nut adaptor, torque the rotor bearing nut to 166 ft. lbs. (225 N-M). Install the oil ring by tilting 30 degree angle and pressing down onto the oil slinger (19).

2.7.6.4. Install the oil ring (20) on the shaft. Slide the oil ring (22) at a 30

degree angle on the oil slinger (20).

2.7.6.5. Heat the thrust bearing (12) to 160°-185° F (71°-85° C). Quickly slide the thrust bearing onto the driveshaft and against the oil slinger (20) with the wide shoulder of the inner race against the shoulder of the oil slinger.

2.7.6.6. Place the spacer set (23) on the thrust bearing.

R11 2x2 19

2.7.6.7. Heat the inner race of the radial bearing (13) to 160°-185° F (71°-85° C). Quickly slide the race over the driveshaft and against the spacer set (23).

2.7.6.8. Install the outer race of the radial bearing (30).

NOTE: Check to see if oil slinger (20) will rotate freely after bearings are installed. If oil slinger (20) rotates freely, place the used bearing locknut (36) back onto the shaft. Tighten bearing locknut using the bearing locknut torque wrench adaptor until the oil slinger (15) is secured. Do not exceed 400 ft. lbs. (542 N.M.).

Remove used bearing locknut (36) and discard.

2.7.6.9. Install new bearing locknut using the bearing nut adaptor, torque the bearing to 130 ft. lbs. (176 M-N).

2.7.6.10. Position the excluder (85) against the driveshaft (5) shoulder.

2.7.6.11. Lubricate and install the rotor o-ring (12) into the groove on the rotor

(3) lip. Install the three rotor guide pins into the rotor.

2.7.6.12. Lubricate and install the rotor drain plugs (8) in the rotor cover (4). Torque to 13 ft. lbs (18 N-M).

2.7.6.13. Being extremely careful not to damage the seal mating ring (78)

cavity, slide the pick-up tube (1) with the protective shield through the opening in the rotor cover (4).

2.7.6.14. Holding the pick-up tube centered, align the rotor and rotor cover

match marks.

2.7.6.15. Guide the rotor cover (4) over the rotor guide pins and against the rotor (3).

2.7.6.16. Match the twelve socket head capscrews (7) with their correct

positions in the rotor cover (4).

2.7.6.17. Seat the rotor cover (4) by evenly threading the socket head capscrews (7). Replace the rotor guide pins with capscrews and torque all to 47 ft. lbs. (6N-M).

2.7.6.18. Insure that the shims (38) are in place and flat against the bearing

cap (14).

2.7.6.19. Thread the rotor alignment rod into a threaded hole in the endplate (15). Install the three eyebolts in the rotor cover (4) threaded holes and adjust the eyebolt nuts until flush against the rotor cover.

R11 2x2 20

2.7.6.20. Suspend the rotor cover with the driveshaft downward above the pedestal (17). Feed the rotor alignment rod into one hole in the pedestal such that the slot in the end plate (15) is aligned with oil return hole in the pedestal.

2.7.6.21. Position the oil rings (22) into the grooves in the oil slinger (20) and

the rotor oil slinger (19). Being careful to keep driveshaft (5) straight, lower the assembly into he pedestal while continuing to feed the alignment rod.

2.7.6.22. Remove the rotor alignment rod and fasten the endplate (15) to the

pedestal (17) with the four hex head capscrews (58). Torque to 20 ft. lbs. (27 N-M).

2.7.6.23. Lubricate and install the seal mating ring o-ring (69) in the rotor

cover (4). Lubricate the seal mating ring cavity in the rotor cover with light oil.

2.7.6.24. Slide the seal mating ring (78) over the pick-up tube (1).

2.7.6.25. Align the hole in seal mating ring with the drive pin (92) in the rotor

cover (4). Slide the seal mating ring into place until flush against the rotor cover.

NOTE: For proper bearing and seal location refer to section 5.0 for shimming.

2.7.6.26. Lubricate and install the pick-up tube o-ring (49) and seal o-ring (44)

in the manifold (36). Lubricate the seal cavity in the manifold with light oil. Place the seal spacer (13a) or the flush ring (13b) in the manifold cavity.

2.7.6.27. Using the seal installation tool, insert the seal (75) into the manifold

(36) cavity being careful not to damage the seal face. Install the retaining ring (91) into the manifold groove.

2.7.6.28. Remove the eyebolts from the rotor cover. Install the manifold guide

pins into the pedestal (17) holes. Clean the seal (75) face and the seal mating ring (78). Install manifold puller into the manifold (36).

2.7.6.29. Being extremely careful not to damage the seal (75) or the seal

mating ring (78), guide the pick-up tube through the manifold (36). Remove the protective shield and lower the manifold over the manifold guide pins while holding the pick-up tube guide centered.

2.7.6.30. Remove the manifold guide pins. Seat the manifold (36) to the

pedestal (17) by evenly threading the ten hex head capscrews (94). Torque the capscrews to 72 ft. lbs. (98 N-M).

R11 2x2 21

2.7.6.31. Remove the manifold puller. Using the pick-up tube guide, align the manifold (36) keyway and the pick-up tube (1) keyway. Pull the pick-up tube past the o-ring (49) and against the manifold shoulder. Rotating the driveshaft by hand may make it easier to pull up the pick-up base.

2.7.6.32. Remove the pick-up tube guide. Install the pick-up tube key (82) into

the keyways. Using the lock nut tool, thread lock nut (81) into pick-up tube. Torque lock nut to 217 ft. lbs. (294 N-M).

2.7.6.33. Install oil drain plug (24).

2.7.6.34. Return pump to installation or position with shaft horizontal. Fill

pedestal with oil to the center of the oil sight gauge (68). Insure that the oil rings (22) are in the correct position.

2.7.6.35. Insure that face of pedestal that mates to pedestal cover (18) is

clean. Place gasket on pedestal hole pattern. Fasten the pedestal cover to the pedestal with the four hex head capscrews (57). Torque to 4 ft. lbs. (5 N-M).

2.7.6.36. Using the wrench flats, install the breather filter (67). Install key (43)

and pump sheave. DO NOT hammer in place as the mechanical seal may be damaged.

2.7.6.37. This completes the bearing replacement procedure. The pump may

now be put into operation.

2.8. STAINLESS STEEL MANIFOLD ASSEMBLY NOZZLE AND O-RING REPLACEMENT The following procedure should be used when the o-ring must be changed to be compatible with the fluid being pumped or the nozzle becomes damaged. This assembly is not normally disassembled. The nozzle is an interference fit in the manifold. Refer to figure 2.4.


Nozzle (95) O-Ring, Nozzle (96)

2.8.2. Recommended Special Tools Lock Nut Tool Manifold Puller Pick-Up Tube Guide Seal Puller Manifold Guide Pins


2.8.3.1. Lock out and tag driver.


R11 2x2 22

2.8.3.3. Drain, disconnect and remove all piping from manifold.

2.8.4. Cautions

The following precautions are recommended to insure satisfactory pump operation after assembly.

2.8.4.1. Replace any o-rings that are exposed during the disassembly

process as they may lose their seal integrity and may leak.

2.8.4.2. Be sure all parts are free of dirt, stray metal chips or any foreign matter and have been thoroughly cleaned.

2.8.4.3. All torque values given assume lubrication with molybdenum

disulfide on threads and underside of capscrew heads. Refer to figure 2.4 for torque values.

2.8.5. Disassembly

The following instructions are applicable to replacement with the pump being in a shaft horizontal position. Refer to Figure 2.4 as well as Section 6.0.

2.8.5.1. Using the lock nut tool, unthread and remove the lock nut (81) which

secures the pick-up tube (1) to the manifold (36). Note that this is a left handed thread.

2.8.5.2. Fully thread the pick-up tube guide into the pick-up tube (1). Lightly

tap on pick-up tube guide until the pick-up tube moves free of the o-ring (49).

2.8.5.3. Install the manifold puller in manifold (36) outlet. Remove the ten

hex head capscrews (94) which secure the manifold (36) to the pedestal (17).

2.8.5.4. Install the manifold guide pins and evenly thread two of the hex head

capscrews (94) into the threaded holes in the manifold until the manifold moves free of the pedestal. Carefully guide the manifold over the pick-up tube until the pick-up tube guide is cleared. Remove the manifold puller and place the manifold on a flat surface with the seal (75) down.

2.8.5.5. Remove the four socket head capscrews (97) that secure the nozzle

to the manifold.

2.8.5.6. Evenly thread two of the socket head capscrews (97) into the threaded holes in the nozzle until the nozzle is released from the manifold (36).

2.8.6. Assembly

After the parts have been cleaned and inspected, the assembly process can

R11 2x2 23

be started.

2.8.6.1. Lubricate and install a new nozzle o-ring (96) in the nozzle (95) groove.

2.8.6.2. Set the nozzle (95) into the manifold (36) with the keyway at the top.

Evenly thread all four of the socket head capscrews (97) into the threaded holes in the manifold (36). Evenly tighten the capscrews until the nozzle is pulled into position. Then torque to 47 ft. lbs. (64 NM).

2.8.6.3. Lubricate and install the pick-up tube o-ring (49) in the manifold (36).

2.8.6.4. Clean the seal (75) face and the seal mating ring (78). Install

manifold puller into the manifold (36).

2.8.6.5. Being extremely careful not to damage the seal (75) or the seal mating ring (78), guide the pick-up tube through the manifold (36). Remove the protective shield ad lower the manifold over the manifold guide pins while holding the pick-up tube guide centered.

2.8.6.6. Remove the manifold guide pins. Seat the manifold (36) to the

pedestal (17) by evenly threading the ten hex head capscrews (94). Torque the capscrews to 72 ft. lbs. (98 NM).

2.8.6.7. Remove the manifold puller. Using the pick-up tube guide, align the

manifold (36) keyway and the pick-up tube (1) keyway. Pull the pick-up tube past the o-ring (49) and against the manifold shoulder. rotating the driveshaft by hand may make it easier to pull up the pick-up tube.

2.8.6.8. Remove the pick-up tube guide. Install the pick-up tube key (82) into

the keyways. Using the lock nut tool, thread lock nut (81) into pick-up tube. Torque lock nut to 217 ft. lbs. (294 NM).

2.8.6.9. This completes the nozzle and nozzle o-ring replacement procedure

2.9. MAJOR COMPONENT REPLACEMENT

The following instructions are included in the event that the rotor, rotor cover or drive shaft need replaced or other repairs are necessary. Refer to figure 2.4 as well as section 6.0. Alternately, a stacked and balanced rotor assembly may be ordered and installed by following the instruction of Section 2.7.5.14 to 2.7.5.15 and 2.7.6.12 to 2.7.6.36. Caution: Replacement of the rotor, rotor cover or driveshaft will require balancing of the rotating assembly and shimming of the pump.

2.9.1. Disassembly

2.9.1.1. Follow replacement instructions in Section 2.7 to 2.7.5.

R11 2x2 24

2.9.1.2. Remove bearing cap (14) by removing the four hex head capscrews (60) that secure the bearing cap to the pedestal (17). Remove the shims (38) and the bearing cap o-ring (52).

2.9.1.3. Driveshaft/Rotor Disassembly:

Remove the six socket head capscrews (83) which secure the driveshaft (5) to the rotor (3). Evenly thread two of the socket head capscrews (83) into the threaded holes in the driveshaft until the driveshaft is released from the rotor.

2.9.2. Hydrostatic Pressure Testing

If required, the manifold, rotor and rotor cover can be hydrostatic pressure tested at this stage. The pump cannot be hydrostatic pressure tested as a completely assembled unit. Refer to section 3.0 for hydrostatic pressure testing.

2.9.3. Assembly

2.9.3.1. Driveshaft/Rotor Assembly

Heat the driveshaft bore of the rotor (3) to 140°-160° F. Install the rotor guide pins and insert the drive shaft into the rotor. Install the six socket head capscrews (83) and torque to 72 ft. lbs. (98 N-M)

2.9.3.2. Install o-ring (52) in bearing cap (14) groove. Fasten the bearing cap to the pedestal (17) with the four hex head capscrews (60). Torque to 72 ft. lbs. (98 N-M).

2.9.3.3. Follow assembly instructions of Section 2.7.6 to 2.7.6.9. If not

previously assembled, attach rotor cover (4) to rotor (3) per Section 2.7.6.10, 2.7.6.11, 2.7.6.14 and 2.7.6.16.

2.9.3.4. Balance the assembly per Section 4.0.

2.9.3.5. Continue assembly per Section 2.7.6.10 to 2.7.6.24 omitting Section

2.7.6.17.

2.9.3.6. Shim per Section 5.0.

3. HYDROSTATIC PRESSURE TESTING

Hydrostatic pressure testing can be done on the rotor and rotor cover as an assembly. The manifold must be tested separately.

3.1. Manifold

R11 2x2 25

3.1.1. Plug inlet and outlet and seal cavity.

3.1.2. Fill completely with water. Pressurize to 300 psig (20.7 bar) and hold for 10 minutes.

3.2. Rotor and Rotor Cover

3.2.1. Assemble rotor cover to rotor per Section 2.7.6.10, 2.7.6.11, 2.7.6.14 and 2.7.6.16.

3.2.2. Fill completely with water and plug rotor cover opening. Pressurize to 300 psig (20.7 bar) and hold for 10 minutes.

3.2.3. Drain.

3.2.4. Complete assembly per Section 2.9.3.

4. ROTOR ASSEMBLY BALANCING

Dynamic balancing of the pump's rotating assembly is necessary to eliminate excessive out-of-balance conditions which can cause vibration damage to the pump. Although each pump is dynamic balanced at the factory prior to shipment, factors, such as a change in the fluid specific gravity or extensive repairs on the pump may require the rebalancing of the rotating assembly. The following instructions are applicable to a completely assembled rotor assembly as listed on figure 2.4.

4.1. Completely fill rotor cavity with fluid of required specific gravity. Plug rotor cover opening.

4.2. Position half key in driveshaft keyway.

4.3. Two plane balance using surfaces indicated by A and B on figure 4.0. Trim balance to 1/2 of the

out of balance by drilling as indicated on figure 4.0. Balance within .20 in-oz (158 mm-g) max at 975 to 1000 rpm. Caution: Sufficient guarding should be used when balancing the rotating assembly.

4.4. Drain the rotor cavity and remove the rotor cover per Section 2.7.5.14 and 2.7.5.15.

R11 2x2 26

Figure 4.0

R11 2x2 27

5. SHIMMING

Variation in components can affect the number of shims necessary to properly pre-load the bearings and correctly compress the mechanical seal. Referring to figure 4.0, the distance between the seal mating ring face and the pedestal flange face is indicated by "C". In a properly shimmed pump, the distance should measure between 0.864" (21.95 mm) and 0.900" (22.86 mm). The following instructions are to determine the required number of shims. WARNING: Before lifting the pump into the vertical position first remove the lifting eye and install the swivel hoist. When tightening the swivel hoist ring, torque to 100ft-lbs. Once the pump is re-assembled and in the horizontal position remove the swivel hoist and re-install the lifting eye. Reference APPENDIX A Drawing.

5.1. For proper bearing and seal location, dimension "C" (as shown in Figure 4.0) must be controlled.

Use the shimming bar (P/N 060580635) and a depth micrometer to measure the seal height. The seal height measurement is then subtracted from the number stamped on the measuring bar. This will give you dimension "C."

5.2. Referring to the shim chart below, find the line in which the measured value "C" falls. Follow the

line across and identify the number of shims required. (The shim chart is based on shims .010" thick, actual thickness may vary.)

5.3. Tilt the pump from its vertical position to a horizontal position. Remove the capscrews and

bearing cap. Install the required number of shims (as shown in figure 4.0).

5.4. Reassemble the bearing cap and four capscrews and torque to 35 ft. lbs. Be sure the drain port is downward.

5.5. Recheck by measuring the distance "C" and checking the shim chart to insure that no additional

shims are required.

5.6. Complete assembly per Section 2.7.6.25 - 2.7.6.36.

SHIMMING CHART SHIMMING CHART

Measured Reading "C" Number of Shims Required

Measured Reading "C" Number of Shims

Required

Inches Millimeters Inches Millimeters

.864 - .900 21.95 - 22.86 0 .814 - .823 20.68 - 20.92 5

.854 - .863 21.69 - 21.94 1 .804 - .813 20.42 - 20.67 6

.844 - .853 21.44 - 21.68 2 .794 - .803 20.17 - 20.41 7

.834 - .843 21.18 - 21.43 3 .784 - .793 19.91 - 20.16 8

.824 - .833 20.93 - 21.17 4

R11 2x2 28

6. PARTS

6.1. SPARE PARTS LIST

The following is the recommended minimum spare parts. Refer to Figures 2.4 and 2.5.

Item No.

Description

Part No.

4 Seal Kit, Standard 0661632-CT

25 Drain Plug, Rotor Cover Steel/Nitrile Stainless Steel/Nitrile

060068656 060068677

26 Bearing Kit (See page 8) 0661950

6.2. MAINTENANCE SUPPLIES

Item No.

Description

Part No.

1 Anti-Seize - Molybdenum Disulfide (1 lb.) 0661261

6.3. ACCESSORIES

Item No.

Description

Part No.

1 Valve and Gauge Package - 2" Steel w/ 3/32" Orifice 0683831

2 Valve ad Gauge Package - 2" Steel w/ 1/8" Orifice 0683831-125

3 Valve and Gauge Package - 2" Steel w/ 5/32" Orifice 0682641

4 Orifice 3/32" 0682444

5 Orifice 1/8" 0682445

6 Orifice 5/32" 0682446

6.4. ORDERING PARTS

6.4.1. General - It is Roto-Jet Pump's policy to continually improve its products. Therefore, specifications are subject to change without notice. Parts should be ordered as far in advance of their use as possible since circumstances beyond our control may reduce existing stock.

R11 2x2 29

6.4.2. Placing Orders - The satisfactory ordering and receiving of parts is dependent upon specific and correct information supplied by the purchaser. A specification sheet for each unit manufactured is on file at the factory, and in case some special part is needed, it can be provided if the correct model and serial number is given. Many unnecessary errors and delays may be eliminated by observing the following instructions.

Your parts order should state:

1. Model and serial number of pump. 2. Part number, description, and quantity required. 3. Your company name, address and zip code clearly. 4. Specific shipping and billing instructions. 5. Date required.

With this assistance, the time required to expedite your order will be greatly reduced. Note: Parts will be furnished in original materials unless specified as a material change. All material substitutions should be discussed with the factory.

6.4.3. Assistance - Should you need any assistance, please contact the factory or nearest regional office listed on the back cover.

R11 2x2 30

7. MAINTENANCE RECORD

DATE

SERIAL NO.

MAINTENANCE RECORD BY:

R11 2x2 31

8. APPENDIX A

When using the swivel hoist, use in place of this lifting eye.

Specification in this manual are subject to change without prior notification. Manual # RJ-DA-3 (11/19) 2019

For optimum service and technical assistance, please contact our factory for the distributor or representative

nearest to your project:

Trillium Flow Technologies Tel 801-359-8731 Fax 801-530-7828

1. GENERAL1.1. INTRODUCTION1.2. ROTO-JET PUMP DESIGN1.3. PUMP IDENTIFICATION

2. DISASSEMBLY/ASSEMBLY2.1. GENERAL2.2. RECOMMENDED TOOLS2.2.1. Assembly Stands

2.3. DISASSEMBLY/ASSEMBLY STANDS2.3.1. Model R11 Dimensional Drawing

2.4. R11 PUMP SECTION DRAWING2.4.1. Parts List - R11 Pump

2.5. SEAL OPTION DRAWING2.6. SEAL REPLACEMENT PROCEDURE2.6.1. Recommended Parts2.6.2. Recommended Special Tools2.6.3. Preparations for Disassembly2.6.3.1. Lock out and tag the driver.2.6.3.2. Blank off and drain the suction and discharge lines.2.6.3.3. Disconnect and remove all piping from the manifold.

2.6.4. Cautions:2.6.4.1. Always replace any o-rings that are exposed during disassembly as they can lose their seal integrity and may leak.2.6.4.2. Be sure all parts are free from dirt, stray metal chips or any foreign matter and have been thoroughly cleaned.2.6.4.3. All torque values assume lubrication with molybdenum disulfide on threads and underside of capscrew heads. Refer to figure 2.4 for torque values.2.6.4.4. When lifting the pump into the vertical position with or without the use of the assembly stand a swivel hoist ring shall be used in place of the lifting eye bolt.2.6.4.5. When tightening the swivel hoist ring provided with the assembly stand kit (060580652-K1), torque to 100ft-lbs.

2.6.5. Disassembly:2.6.5.1. Using the lock nut tool, unthread and remove the lock nut (81) which secures the pick-up tube (1) to the manifold (36). Note that this is a left-hand thread.2.6.5.2. Fully thread the pick-up tube guide into the pick-up tube (1). Tap lightly on the pick-up tube guide until the pick-up tube clears the o-ring (49).2.6.5.3. Remove the ten hex head cap screws (94) which secure the manifold (36) to the pedestal (17). Install two manifold guide pins into two threaded holes in the pedestal (17) at the two o'clock and ten o'clock positions.2.6.5.4. Evenly thread two of the hex head cap screws (94) into the threaded holes in the manifold (36) until the manifold moves free of the pedestal (17). Carefully guide the manifold over the pick-up tube until the pick-up tube guide is cleared. P...2.6.5.5. Remove the seal retaining ring (91) from the manifold. Grasping the inside diameter of the seal spacer (13a) or the flush ring (13b), pull to remove the seal (75) along with the seal spacer or the flush ring. If unable to remove by hand, re...2.6.5.6. Remove the pick-up tube o-ring (49) and the seal o-ring (44).2.6.5.7. Place a rubber protective shield between the pick-up tube (1) and the seal mating ring (78). Remove the key (82) from the pick-up tube.2.6.5.8. Grasping the outside diameter of the seal mating ring (78), pull to remove. If unable to remove by hand, install the seal mating ring puller and evenly thread the two capscrews against the rotor cover (4) until the seal mating ring is free o...2.6.5.9. Remove the seal mating ring o-ring (69).

2.6.6. Assembly:2.6.6.1. Lubricate and install the seal mating ring o-ring (69) in the rotor cover (4). Lubricate the seal mating ring cavity with light oil.2.6.6.2. Carefully guide the seal mating ring (78) over the pick-up tube guide and the pick-up tube (1). Align the hole in the seal mating ring with the driver pin (92) in the rotor cover (4). Slide the seal mating ring into place until flush agains...2.6.6.3. Lubricate and install the pick-up tube o-ring (49) and the seal o-ring (44) in the manifold (65). Lubricate the seal cavity in the manifold with light oil. Place the seal spacer (13a) or the flush ring (13b) in the manifold cavity.2.6.6.4. Using the seal installation tool, insert the seal (75) into the manifold (36) cavity being careful not to damage the seal face. Install the retaining ring (91) into the manifold groove.2.6.6.5. Clean seal face and the seal mating ring face. Remove protective shield.2.6.6.6. Being extremely careful not to damage seal or seal mating ring, install manifold (36). Slide pick-up tube guide through manifold. Align manifold on manifold guide pins and slide into place on pedestal while holding pick-up guide centered.2.6.6.7. Remove the manifold guide pins and seat the manifold (36) into the pedestal (17) by evenly torquing the ten hex head capscrews (94). Torque the capscrews to 72 ft. lbs. (98 N-M).2.6.6.8. Using the pick-up tube guide, align the manifold (36) keyway and the pick-up tube (1) keyway. Pull the pick-up tube past the o-ring (49) and against the manifold shoulder. Remove the pick-up tube guide.2.6.6.9. Install the pick-up tube key (82) into the keyways. Using the lock nut tool, thread lock nut (81) into pick-up tube. Torque lock nut to 217 ft. lbs. (294 N-M).2.6.6.10. This completes the seal replacement procedure. The pump may be put back into operation. Connect all piping and refer to Section 3.3 for start up procedures.

2.7. BEARING REPLACEMENT PROCEDURE:2.7.1. Recommended Parts2.7.2. Recommended Special Tools2.7.3. Preparations for Disassembly2.7.3.1. Lock out and tag the driver.2.7.3.2. Blank off and drain the suction and discharge lines.2.7.3.3. Remove belt guard; slack off belt tension and remove belts; remove pump sheave and key (43).2.7.3.4. Drain, disconnect and remove all piping from the manifold.2.7.3.5. Remove oil drain plug (24) and drain pedestal oil.2.7.3.6. Drain rotor by removing the rotor drain plug (42) from the manifold (36). Rotate drive shaft (5) until the rotor cover drain plug (8) is visible through the unplugged hole in the manifold (36). Remove the rotor cover drain plug and rotate t...

2.7.4. Cautions2.7.4.1. Replace any o-rings that are exposed during the pump disassembly process as they lose their seal integrity and may leak.2.7.4.2. Be sure all parts are free of dirt, stray metal chips or any foreign matter and have been thoroughly cleaned.2.7.4.3. All torque valves given assume lubrication with molybdenum disulfide on threads and underside of capscrew heads. Refer to figure 2.4 for torque values.2.7.4.4. When replacing pick-up tube, replace pick-up tube lock nut to avoid attachment complication.2.7.4.5. Always install new bearing nuts when replacing bearings. As they lose their positive locking capability when removed.2.7.4.6. All three bearings should be replaced as a set.2.7.4.7. To avoid creating an out of balance condition that makes the pump susceptible to vibration damage, match mark capscrew and component relative positions for reassembly into same positions.2.7.4.8. Replacement of the rotor, rotor cover or drive shaft will require balancing of rotating assembly and shimming of pump. See section 2.9.2.7.4.9. WARNING: When lifting the pump into the vertical position with or without the use of the assembly stand a swivel hoist ring shall be used in place of the lifting eye. Reference APPENDIX A Drawing.

2.7.5. Disassembly2.7.5.1. Using the lock nut tool, unthread and remove the lock nut (81) which secures the pick-up tube (1) to the manifold (36). Note that this is a left handed thread.2.7.5.2. Fully thread the pick-up tube guide into the pick-up tube (1). Lightly tap on pick-up tube guide until the pick-up tube moves free of the o-ring (49).2.7.5.3. Install the manifold puller in manifold (36) outlet. Remove the ten hex head capscrews (94) which secure the manifold (36) to the pedestal (17).2.7.5.4. Install the manifold guide pins and evenly thread two of the hex head capscrews (94) into the threaded holes in the manifold over the pick-up tube until the pick-up tube guide is cleared. Remove the manifold puller ad place the manifold on a...2.7.5.5. Place a protective shield between the pick-up tube and the seal mating ring (78). Remove the key (82) from the pick-up tube keyway.2.7.5.6. Remove the seal retaining ring (91) from the manifold (36). Grasping the inside diameter of the seal spacer (13a) or the flush ring (13b), pull to remove the seal (75) along with the seal spacer or the flush ring. If unable to remove by han...2.7.5.7. Remove the pick-up tube o-ring (49) and the seal o-ring (44).2.7.5.8. Remove the four hex head capscrews (58) which attach to the end plate (15) to the pedestal (17).2.7.5.9. Using the wrench flats, unthread and remove the breather filter (67).2.7.5.10. Remove the four hex head capscrews (57) which attach the pedestal cover (18) to the pedestal (17). Remove the pedestal cover. Remove gasket (34) from the pedestal.2.7.5.11. Position the two oil rings (22) into the grooves of the rotor oil slinger (19) and the oil slinger (20).2.7.5.12. Thread the three eyebolts into three evenly spaced holes in the rotor cover (4). Adjust the eyebolt nuts until flush against the rotor cover.2.7.5.13. Using a sling, lift and guide the rotor cover (3), the driveshaft (5) and the bearings out of the pedestal (17). Being careful not to damage rotor cover hub, place the assembly on a flat surface or mount with rotor cover upward.2.7.5.14. Match mark the location of each of the twelve socket head cap screws (7) which secure the rotor cover (4) to the rotor (3).2.7.5.15. Remove the twelve socket head capscrews (7) and install the rotor guide pins. Evenly thread three of the socket head capscrews (7) into the threaded holes in the rotor cover until the rotor cover is released from the rotor. Replace the thr...2.7.5.16. Holding the pick-up tube (1) centered in the rotor cover (4), lift the rotor cover.2.7.5.17. Guide the pick-up tube out of the rotor cover. Place the rotor cover on a flat surface with the seal mating ring visible. Remove the rotor guide pin.2.7.5.18. Grasping the outside diameter of the seal mating ring (78), pull to remove from the rotor cover (4). If unable to remove by hand, install the seal mating ring puller and evenly thread the two capscrews against the rotor cover until the seal...2.7.5.19. Remove the seal mating ring o-ring (69) and rotor o-ring (12).2.7.5.20. Being careful not to damage rotor lip, position assembly with shaft up and vertical.2.7.5.21. Remove the excluder (85). Using the bearing nut adaptor, remove the bearing nut (46) and put to the side to be used during bearing assembly. Remove the outer race of the radial bearing (13) and the outer ring of the spacer set (23).2.7.5.22. Install the bearing puller under the oil slinger (20). Adjust the bearing puller until the thrust bearing is free of the drive shaft (5). Remove the inner race of the radial bearing (13), inner ring of spacer set (23), thrust bearing (12),...2.7.5.23. Using rotor bearing nut adaptor, remove the rotor bearing nut (47). Do not reuse.2.7.5.24. Install the bearing puller under the spacer (21). Adjust the bearing puller until the bearing (11) is free of the drive shaft.2.7.5.25. Remove the rotor oil slinger (19), oil ring (22), rotor bearing (11), wave spring (66), spacer (21), and endplate (15). Remove endplate o-ring (56) from endplate.

2.7.6. Assembly2.7.6.1. Install with enter edge of lip seal (98) facing down into the endplate (15). Lubricate and install the endplate o-ring (56), in the endplate groove. Place the endplate, the wave spring (66) and spacer (21) into position on the driveshaft (5).2.7.6.2. Heat the rotor bearing (11) to 160 -180 F (71 -82 C). Quickly slide the rotor bearing onto the driveshaft (5) and against the spacer (21).2.7.6.3. Install the rotor oil slinger (19) and the rotor bearing nut (47) on the driveshaft. Using the rotor bearing nut adaptor, torque the rotor bearing nut to 166 ft. lbs. (225 N-M). Install the oil ring by tilting 30 degree angle and pressing d...2.7.6.4. Install the oil ring (20) on the shaft. Slide the oil ring (22) at a 30 degree angle on the oil slinger (20).2.7.6.5. Heat the thrust bearing (12) to 160 -185 F (71 -85 C). Quickly slide the thrust bearing onto the driveshaft and against the oil slinger (20) with the wide shoulder of the inner race against the shoulder of the oil slinger.2.7.6.6. Place the spacer set (23) on the thrust bearing.2.7.6.7. Heat the inner race of the radial bearing (13) to 160 -185 F (71 -85 C). Quickly slide the race over the driveshaft and against the spacer set (23).2.7.6.8. Install the outer race of the radial bearing (30).2.7.6.9. Install new bearing locknut using the bearing nut adaptor, torque the bearing to 130 ft. lbs. (176 M-N).2.7.6.10. Position the excluder (85) against the driveshaft (5) shoulder.2.7.6.11. Lubricate and install the rotor o-ring (12) into the groove on the rotor (3) lip. Install the three rotor guide pins into the rotor.2.7.6.12. Lubricate and install the rotor drain plugs (8) in the rotor cover (4). Torque to 13 ft. lbs (18 N-M).2.7.6.13. Being extremely careful not to damage the seal mating ring (78) cavity, slide the pick-up tube (1) with the protective shield through the opening in the rotor cover (4).2.7.6.14. Holding the pick-up tube centered, align the rotor and rotor cover match marks.2.7.6.15. Guide the rotor cover (4) over the rotor guide pins and against the rotor (3).2.7.6.16. Match the twelve socket head capscrews (7) with their correct positions in the rotor cover (4).2.7.6.17. Seat the rotor cover (4) by evenly threading the socket head capscrews (7). Replace the rotor guide pins with capscrews and torque all to 47 ft. lbs. (6N-M).2.7.6.18. Insure that the shims (38) are in place and flat against the bearing cap (14).2.7.6.19. Thread the rotor alignment rod into a threaded hole in the endplate (15). Install the three eyebolts in the rotor cover (4) threaded holes and adjust the eyebolt nuts until flush against the rotor cover.2.7.6.20. Suspend the rotor cover with the driveshaft downward above the pedestal (17). Feed the rotor alignment rod into one hole in the pedestal such that the slot in the end plate (15) is aligned with oil return hole in the pedestal.2.7.6.21. Position the oil rings (22) into the grooves in the oil slinger (20) and the rotor oil slinger (19). Being careful to keep driveshaft (5) straight, lower the assembly into he pedestal while continuing to feed the alignment rod.2.7.6.22. Remove the rotor alignment rod and fasten the endplate (15) to the pedestal (17) with the four hex head capscrews (58). Torque to 20 ft. lbs. (27 N-M).2.7.6.23. Lubricate and install the seal mating ring o-ring (69) in the rotor cover (4). Lubricate the seal mating ring cavity in the rotor cover with light oil.2.7.6.24. Slide the seal mating ring (78) over the pick-up tube (1).2.7.6.25. Align the hole in seal mating ring with the drive pin (92) in the rotor cover (4). Slide the seal mating ring into place until flush against the rotor cover.2.7.6.26. Lubricate and install the pick-up tube o-ring (49) and seal o-ring (44) in the manifold (36). Lubricate the seal cavity in the manifold with light oil. Place the seal spacer (13a) or the flush ring (13b) in the manifold cavity.2.7.6.27. Using the seal installation tool, insert the seal (75) into the manifold (36) cavity being careful not to damage the seal face. Install the retaining ring (91) into the manifold groove.2.7.6.28. Remove the eyebolts from the rotor cover. Install the manifold guide pins into the pedestal (17) holes. Clean the seal (75) face and the seal mating ring (78). Install manifold puller into the manifold (36).2.7.6.29. Being extremely careful not to damage the seal (75) or the seal mating ring (78), guide the pick-up tube through the manifold (36). Remove the protective shield and lower the manifold over the manifold guide pins while holding the pick-up t...2.7.6.30. Remove the manifold guide pins. Seat the manifold (36) to the pedestal (17) by evenly threading the ten hex head capscrews (94). Torque the capscrews to 72 ft. lbs. (98 N-M).2.7.6.31. Remove the manifold puller. Using the pick-up tube guide, align the manifold (36) keyway and the pick-up tube (1) keyway. Pull the pick-up tube past the o-ring (49) and against the manifold shoulder. Rotating the driveshaft by hand may ma...2.7.6.32. Remove the pick-up tube guide. Install the pick-up tube key (82) into the keyways. Using the lock nut tool, thread lock nut (81) into pick-up tube. Torque lock nut to 217 ft. lbs. (294 N-M).2.7.6.33. Install oil drain plug (24).2.7.6.34. Return pump to installation or position with shaft horizontal. Fill pedestal with oil to the center of the oil sight gauge (68). Insure that the oil rings (22) are in the correct position.2.7.6.35. Insure that face of pedestal that mates to pedestal cover (18) is clean. Place gasket on pedestal hole pattern. Fasten the pedestal cover to the pedestal with the four hex head capscrews (57). Torque to 4 ft. lbs. (5 N-M).2.7.6.36. Using the wrench flats, install the breather filter (67). Install key (43) and pump sheave. DO NOT hammer in place as the mechanical seal may be damaged.2.7.6.37. This completes the bearing replacement procedure. The pump may now be put into operation.

2.8. STAINLESS STEEL MANIFOLD ASSEMBLY NOZZLE AND O-RING REPLACEMENT2.8.1. Recommended Parts2.8.2. Recommended Special Tools2.8.3. Preparations for Disassembly2.8.3.1. Lock out and tag driver.2.8.3.2. Blank off and drain the suction and discharge lines.2.8.3.3. Drain, disconnect and remove all piping from manifold.

2.8.4. Cautions2.8.4.1. Replace any o-rings that are exposed during the disassembly process as they may lose their seal integrity and may leak.2.8.4.2. Be sure all parts are free of dirt, stray metal chips or any foreign matter and have been thoroughly cleaned.2.8.4.3. All torque values given assume lubrication with molybdenum disulfide on threads and underside of capscrew heads. Refer to figure 2.4 for torque values.

2.8.5. Disassembly2.8.5.1. Using the lock nut tool, unthread and remove the lock nut (81) which secures the pick-up tube (1) to the manifold (36). Note that this is a left handed thread.2.8.5.2. Fully thread the pick-up tube guide into the pick-up tube (1). Lightly tap on pick-up tube guide until the pick-up tube moves free of the o-ring (49).2.8.5.3. Install the manifold puller in manifold (36) outlet. Remove the ten hex head capscrews (94) which secure the manifold (36) to the pedestal (17).2.8.5.4. Install the manifold guide pins and evenly thread two of the hex head capscrews (94) into the threaded holes in the manifold until the manifold moves free of the pedestal. Carefully guide the manifold over the pick-up tube until the pick-up ...2.8.5.5. Remove the four socket head capscrews (97) that secure the nozzle to the manifold.2.8.5.6. Evenly thread two of the socket head capscrews (97) into the threaded holes in the nozzle until the nozzle is released from the manifold (36).

2.8.6. Assembly2.8.6.1. Lubricate and install a new nozzle o-ring (96) in the nozzle (95) groove.2.8.6.2. Set the nozzle (95) into the manifold (36) with the keyway at the top. Evenly thread all four of the socket head capscrews (97) into the threaded holes in the manifold (36). Evenly tighten the capscrews until the nozzle is pulled into posit...2.8.6.3. Lubricate and install the pick-up tube o-ring (49) in the manifold (36).2.8.6.4. Clean the seal (75) face and the seal mating ring (78). Install manifold puller into the manifold (36).2.8.6.5. Being extremely careful not to damage the seal (75) or the seal mating ring (78), guide the pick-up tube through the manifold (36). Remove the protective shield ad lower the manifold over the manifold guide pins while holding the pick-up tub...2.8.6.6. Remove the manifold guide pins. Seat the manifold (36) to the pedestal (17) by evenly threading the ten hex head capscrews (94). Torque the capscrews to 72 ft. lbs. (98 NM).2.8.6.7. Remove the manifold puller. Using the pick-up tube guide, align the manifold (36) keyway and the pick-up tube (1) keyway. Pull the pick-up tube past the o-ring (49) and against the manifold shoulder. rotating the driveshaft by hand may ma...2.8.6.8. Remove the pick-up tube guide. Install the pick-up tube key (82) into the keyways. Using the lock nut tool, thread lock nut (81) into pick-up tube. Torque lock nut to 217 ft. lbs. (294 NM).2.8.6.9. This completes the nozzle and nozzle o-ring replacement procedure

2.9. MAJOR COMPONENT REPLACEMENT2.9.1. Disassembly2.9.1.1. Follow replacement instructions in Section 2.7 to 2.7.5.2.9.1.2. Remove bearing cap (14) by removing the four hex head capscrews (60) that secure the bearing cap to the pedestal (17). Remove the shims (38) and the bearing cap o-ring (52).2.9.1.3. Driveshaft/Rotor Disassembly:

2.9.2. Hydrostatic Pressure Testing2.9.3. Assembly2.9.3.1. Driveshaft/Rotor Assembly2.9.3.2. Install o-ring (52) in bearing cap (14) groove. Fasten the bearing cap to the pedestal (17) with the four hex head capscrews (60). Torque to 72 ft. lbs. (98 N-M).2.9.3.3. Follow assembly instructions of Section 2.7.6 to 2.7.6.9. If not previously assembled, attach rotor cover (4) to rotor (3) per Section 2.7.6.10, 2.7.6.11, 2.7.6.14 and 2.7.6.16.2.9.3.4. Balance the assembly per Section 4.0.2.9.3.5. Continue assembly per Section 2.7.6.10 to 2.7.6.24 omitting Section 2.7.6.17.2.9.3.6. Shim per Section 5.0.

3. HYDROSTATIC PRESSURE TESTING3.1. Manifold3.1.1. Plug inlet and outlet and seal cavity.3.1.2. Fill completely with water. Pressurize to 300 psig (20.7 bar) and hold for 10 minutes.

3.2. Rotor and Rotor Cover3.2.1. Assemble rotor cover to rotor per Section 2.7.6.10, 2.7.6.11, 2.7.6.14 and 2.7.6.16.3.2.2. Fill completely with water and plug rotor cover opening. Pressurize to 300 psig (20.7 bar) and hold for 10 minutes.3.2.3. Drain.3.2.4. Complete assembly per Section 2.9.3.

4. ROTOR ASSEMBLY BALANCING4.1. Completely fill rotor cavity with fluid of required specific gravity. Plug rotor cover opening.4.2. Position half key in driveshaft keyway.4.3. Two plane balance using surfaces indicated by A and B on figure 4.0. Trim balance to 1/2 of the out of balance by drilling as indicated on figure 4.0. Balance within .20 in-oz (158 mm-g) max at 975 to 1000 rpm. Caution: Sufficient guarding shou...4.4. Drain the rotor cavity and remove the rotor cover per Section 2.7.5.14 and 2.7.5.15.

5. SHIMMING5.1. For proper bearing and seal location, dimension "C" (as shown in Figure 4.0) must be controlled. Use the shimming bar (P/N 060580635) and a depth micrometer to measure the seal height. The seal height measurement is then subtracted from the nu...5.2. Referring to the shim chart below, find the line in which the measured value "C" falls. Follow the line across and identify the number of shims required. (The shim chart is based on shims .010" thick, actual thickness may vary.)5.3. Tilt the pump from its vertical position to a horizontal position. Remove the capscrews and bearing cap. Install the required number of shims (as shown in figure 4.0).5.4. Reassemble the bearing cap and four capscrews and torque to 35 ft. lbs. Be sure the drain port is downward.5.5. Recheck by measuring the distance "C" and checking the shim chart to insure that no additional shims are required.5.6. Complete assembly per Section 2.7.6.25 - 2.7.6.36.

6. PARTS6.1. SPARE PARTS LIST6.2. MAINTENANCE SUPPLIES6.3. ACCESSORIES6.4. ORDERING PARTS6.4.1. General - It is Roto-Jet Pump's policy to continually improve its products. Therefore, specifications are subject to change without notice. Parts should be ordered as far in advance of their use as possible since circumstances beyond our cont...6.4.2. Placing Orders - The satisfactory ordering and receiving of parts is dependent upon specific and correct information supplied by the purchaser. A specification sheet for each unit manufactured is on file at the factory, and in case some specia...6.4.3. Assistance - Should you need any assistance, please contact the factory or nearest regional office listed on the back cover.

7. MAINTENANCE RECORD8. APPENDIX A

disassembly/assembly manual r11 2x2 · 2019. 11. 6. · jet design completely eliminates the need...

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