Fismiotn Instruction | Document No.: 116-81-1-0012 | Version: 4.0 Page 1 of 34 Instruction Manual Fuller-Kinyon Type M Pump Grease Lubricated Pressurized Bearings / Seal Assembly Caution Read this instruction manual before performing any installation, operation or maintenance procedure, ‘All equipment must be operated and maintained in accordance with all applicable governmental safety and health laws and regulations, generally recognized industrial standards, and the user’s plant standards. Version Signed by “Release Date 4.0 Lou Dibuo 8/31/2004 Gismiotn F.L.Smidth, Inc, « 2040 Avenue C = Bethlehem, PA 18017-2188 ‘Telephone: 610-264-6011 m Fax: +1-610-264-6701 » www.flsmidth.com Parts and Service Call 1-800-795-6825TABLE OF CONTENTS INTRODUCTION Receiving and Storage... ee 8 INSTALLATION Foundation. . . ee :—=i‘il Erection and Alignment. © 2 a Purge Air Piping... ee eS PRINCIPLE OF OPERATION.» - ee ee ee eee ee eB GQepAC OPERATION, = cs LUBRICATION Bere ss = ee Seals . - Oe Ct Flapper Valve Shaft 72D ee 10 MAINTENANCE Pump Screw. 2 1B Pump screw nenovals 6 0 96 6 2 0g 12 Barrel Bushing Removal. |). ee Dee ee Bh Barrel Bushing Replacement...) . + +--+ + e220 Pump Screw Installation... 2... ee fe ee 122 Installation from Discharge Ends ss 7) St + + 22 Installation from Drive End...) ) ee ee ee ee 28 Bearings... ee ee eRe Bearing Replacement. . 2... oe ee Be Bearing Replacement Drive End of Pump. ++...) . «+ .25 Seal Replacement... - - ee tt ee 2:26 Wear Sleeve Replacement +... ete | 27 Flapper Valve Assembly. ¢ 6 202 2 2 vs BB Pump Screw Construction . +... pe 2 Fuller-Kinyon Pump Screw Inspection Criteria. |)... :29 Troubleshooting Fuller-Kinyon Pumping System... . . . - -30 Typical Piping Arrangement... ..---- +--+ + ++ + +32 Compressor Arrangement... +... +00 eee ee + 034 Sheet 2 of 34INTRODUCTION The Fuller equipment for this installation has been specified and reconmended on the basis of information given to Fuller Company by your company. This installation should operate satisfactorily. If any questions arise concerning the safe operation or performance of the equipment supplied, please communicate with the nearest Fuller Branch or the Service Department at the Main Office at Bethlehem. Do not make any change to the installation or equipment without consulting Fuller Company first. These operating instructions and parts books apply to your particular in- stallation. Extra copies have been supplied and everyone concerned with the operation and maintenance of this equipment should read them. For easy refer- ence, operating and maintenance instructions are listed under the following headings: Principle of Operation, General Operation, Lubrication, and Maintenance. When ordering replacement parts for this equipment, please supply pump machine number, twelve-digit part number, and correct name of part. These can be obtained from the specifications which are a part of this instruction book. RECEIVING AND STORAGE Before and after uncrating, look for damage that may have occurred in transit. Check for shortages by comparing each item received with those listed on the shipping manifest. If damage or shortage is noted, advise the carrier within fifteen days of receipt and request an inspection report. Make proper claim with the carrier and order replacement part(s) from Fuller. If the unit is not installed immediately, place it in a clean, dry, storage area protected from inclement weather. If an extended storage period is necessary, consult Fuller Company Service Department for precautions. INSTALLATION FOUNDATION Concrete foundations, extending to firm bearing and having moderate steel rod reinforcing, are recommended. However, installations on balconies or steel supports are also satisfactory providing that sufficient stiffness is designed into the supports to maintain Fuller-Kinyon pump and drive alignment. Simple slab type foundations are normally used to raise the Fuller-Kinyon pump to a reasonable height above the floor for convenient servicing and inspection. Sheet 3 of 34‘The basic design should be for static loadings only. The foundation drawing indicates the necessary dimensions for the construction of these foundations and gives anchor bolt and pipe sleeve locations. ERECTION AND ALIGNMENT The unit should be placed on its foundation and leveled carefully with wedges located as close to foundation bolts as possible. The drive, with the coup- ling half assembled, should be placed on the foundation and aligned with the unit. All anchor bolt nuts must be sufficiently tight to hold the unit firmly on wedges or on a plate. Check for proper shaft gap (refer to the general ar- rangement drawing) and proceed with coupling alignment. After alignment is complete, proceed as follows: @ Use a cement grout and grout in thoroughly around and well under the base and fill all anchor bolt sleeve openings. © After grout is set, tighten all anchor bolts firmly. Be sure to recheck coupling alignment and realign if necessary. © The drive should be checked for rotation, making sure that it agrees with the Fuller-Kinyon pump rotation arrow. The screw should rotate counter- clockwise when viewed from the drive end. The motor and the pump should not be connected for this check. © For V-belt driven units, locate sheaves as dimensioned on the general arrangement drawing. Check the alignment of the sheaves before final grouting. Install the driver and its base with allowance for lateral motion to install V-belts and provide proper tension during operation. In adjusting tension of V-belts, follow instructions of the V-belt manufacturer. PURGE AIR PIPING Seal purge air must be supplied to both ends of the pump. Refer to figures 4 or 4A for piping arrangements. The piping arrangement shown in figure 4 utilizes manifold air to purge the seals located at both ends of the pump. The air purge piping shown in figure 4A utilizes plant air at both ends of the pump. The pump bill of material specifies the piping arrangement furnished for your installation. CAUTION The purge connection union, located at the drive end of the pump is equipped with an orifice plate. The union at the discharge end of a pump utilizing plant air purge also contains an orifice. Check to insure that the orifice plates are in place vhen assembling piping. Adjust pressure regulators as specified in figure 4a. Sheet 4 of 34PRINCIPLE OF OPERATION Material to be conveyed enters the hopper (A, figure 1), the screw (B) advances the material through the barrel (C) to the discharge body (D). In the discharge body, the material is compressed to form a material seal. The material seal prevents a reverse flow of conveying air from the mixing chanber (E). The screw has a reverse pitch flight (F) which repels material thus aiding the advancing screw flights in forcing the material into the mixing chanber.. After the material is discharged into the mixing chanber (E), compressed air - entering the mixing chamber through the nozzles (G) - fluidizes it suffi- ciently to permit pumping through the transport line connected to the end of the mixing chamber. The free-floating flapper valve (H), located in the discharge area of the pump, is @ mechanical seal which assists in preventing the reverse flow of air from the mixing chamber through the pump barrel. The external flapper valve lever (T) serves as a visual indication that the free-floating flapper valve is operating satisfactorily. This external lever should never be connected by any means to the internal valve. A counterweight (U) is attached to the flapper valve handle to aid in maintaining a material seal. This counterweight position is adjustable along the flapper valve handle to increase or decrease flapper valve pressure. Each pump is supplied with one spacer ring (V) located behind the flapper valve assembly. The proper combination of counterweight (U) plus spacer ring (V) should provide an adequate material seal for proper operation. In some cases, the spacer (V) can be removed to achieve the desired balance between material seal and motor load. The pump screw is coupled to a drive motor by either a shaft coupling or a V-belt drive. The screw pitch and speed are determined by Fuller Company for each application. The Fuller-Kinyon pump will operate most efficiently at the maximun capacity for which it was sized. However, it is permissible to operate the type M pump at reduced load conditions. 20 Ske FG. 25, 26,2¢ SEE Fig. 34,36,3¢ Sheet 5 of 34GENERAL OPERATION Carefully observe the following thirteen points prior to initial start-up and during subsequent operation of the Fuller-Kinyon system. a, Assuming an individual compressor* is part of the Fuller-Kinyon system, check the intake duct for loose dirt or other foreign material; then check alignment, orientation, and lubrication of the compressor. (Refer to Compressor Instructions for details.) If the air supply is from an individual compressor to an individual pump, no valve should be in the air line between the compressor and the Fuller-Kinyon pump. The Fuller-Kinyon pup is a precision piece of machinery which requires a rigid foundation. For maximm maintenance-free operation, the pump base must be flat, true, and anchored solidly in the foundation. If the above is not adhered to, distortion of the Fuller-Kinyon pump will occur, thereby putting undue strain on the pump components. There are two drive options for the Fuller-Kinyon pump, either V-belt or direct coupling drive. If a coupling drive is used, disconnect the coupling and verify the proper alignment between the motor and the pump coupling halves. Coupling misalignment may cause premature bearing failures and pump vibration. In those instances where a V-belt drive is used, verify the alignnent between the pump and motor sheaves. Inspect the Fuller-Kinyon pump hopper, mixing chamber, and air manifold for foreign material. Carefully observe the operating instructions furnished before starting the compressor. On both ends of the Fuller-Kinyon pump, housed in the bearing housing supports (A, figure 4), there are seal arrangements which require a steady flow of air or air purge for proper operation. The Fuller-Kinyon Pump must never be run without purge air to the seal arrangement. Start the Fuller-Kinyon pump motor only after air is entering the pump. Check the Fuller-Kinyon pump screw rotation; it should be counterclock- wise when viewed from the motor end. Start the Fuller-Kinyon pump without feed. Note the pressure on the manifold gauge and line gauge. For pumps utilizing manifold air for seal purge the manifold pressure gauge (J, figure 1) should indicate 8 to 9 psi (.56 to .63 kg/cm?) higher than the line pressure gauge (K). For Pumps utilizing plant air, the manifold pressure gauge should be 5 psi (.35_ kg/cm) higher than line pressure. Without feed, the line pressure should be nearly zero in each case. *"Individual compressor" refers to a compressor whose sole purpose is to supply air to the Fuller-Kinyon pump. Normally it is a rotary machine with no aftercooler or receiver in the system. Sheet 6 of 3410. a. 12. 13. Open the feed valve or start the feed conveying equipment. As the load through the Fuller-Kinyon pump increases, the pressure on both the manifold gauge (5) and line gauge (K) will’ rise. The pressure on gauge (3) will always be higher than on gauge (K) throughout the full operating range. If, with normal full feed, the pressure on the gauge (K) fluctuates continuously from high to low readings, the amperage of the pump motor varies through the same cycle, and the flapper valve lever (1) contin- ually moves up and down, blowback through the Fuller-Kinyon pump material seal is indicated. Adjust the counterweight (U) to a position farther out on the flapper valve lever (T). If there is indication of continuous overload on the motor, remove the spacer plate (V) and readjust the counterweight (U) until steady operation is maintained. If the blowback condition persists for a long period of time, consult Fuller Company. When shutting down the Fuller-Kinyon pump, first stop the material flow and after the pump is completely empty, stop the driving motor. When the Fuller-Kinyon pump screw has come to a complete stop, the air should be allowed to blow through the transport line until gauge (K) stabilizes at nearly zero. When the material feed rate to the Fuller-Kinyon pump is not controlled (under silos, bins, tanks, railroad cars, etc.), a solenoid air valve complete with an instantaneous trip relay is part of the Fuller-Kinyon pump equipment. (See figures 4 and 4A.) In operation, when the material flow to the Fuller-Kinyon pump becomes excessive, and the pump motor overloads, the trip relay then operates the solenoid air valve (C) and air is admitted into the Fuller-Kinyon pump hopper. This reduces the Fuller-Kinyon pump motor overload condition and when the motor load becomes normal again, the solenoid valve closes. ‘The instantaneous trip relay is set at 95% of the motor full-load current and the reset point is 82% of the trip relay setting. The pipe union (D) contains an orifice which meters air through the line (B) to keep it clear. Care must be taken during disassembly and reassembly to insure that the orifice remains in place. LUBRICATION BEARINGS For lubrication use a highly stable EP grease, preferably Bentone base, suitable for antifriction bearing lubrication at temperatures from 0°F to +300°F (-18°C to 149°C). It must meet the following specifications: Sheet 7 of 34Worked Penetration NLGI No. 2 Grade ASTM D-217 Dropping Point Minimum 410°F (210°C) ASTM D-566 Grease Shear Stability Maximum 10% Change ASTM D-2178 10,000 Strokes Roll Stability Maximum 25% Change ASTM D-1831 2 Hours Grease Oxidation Maximum 20 psi Drop (1.4 kg/cm?) ASTN D-942 Wheel Bearing Test Maximum 5% Loss ASTH D-1263 6 Hours @ 235° (113°C) Timken EP Test Minimum 40 1b (18 kg) ASTM D=2509 Four Ball EP Test LWI - Minimum 30.0 ASTM D-2596 Four Ball Wear Test Weld Point - Minimun ASTM D-2266 200 kg Maximum 0.60 mm Scar Diam Compliance with the above specifications in no way lessens the responsibility of the lubricant supplier to furnish products that perform satisfactorily in the application for which they are recommended. Original equipment bearings and replacement bearings are prelubricated with grease conforming to the above specifications. Relubrication with one of the following greases is reconmended: Shell 0i1 Company - Darina EP2, Aero Shell No. 5 Keystone Precision Lubricants - Moly 53 Light Before changing to lubricants of another manufacture, the supplier of the new product must show, to the satisfaction of the user, evidence of compatibility with the product being replaced. It must satisfy the specifications listed above and perform equally as well as the one replaced. Failure to do this may result in permanent damage to the antifriction bearings. Sheet 8 of 34We recommend that pumps operating continuously twenty-four hours a day be relubricated either monthly or every 700 hours of operation. This time interval is the suggested starting interval for a maintenance program. Check the grease for oiliness and dirt and adjust the greasing frequency accord- ingly. It is important to maintain the proper amount of grease within the bearing housings. An excessive quantity of grease will result in high ‘temperatures and subsequent damage to the bearing. The best performance and reliability may be achieved by periodically removing the bearings, flushing them clean with a suitable solvent, and repacking them with the proper, fresh lubricant. The old grease in the bearing housing and retainer should be removed before reassembly. NOTE Grease bearings while the pump is running. When lubricating the drive end bearing, inject a generous amount of grease (do not fill the cavity) through fittings (A) on figures 3a, 3b, and 3c. Allow the pump to run until bearings attain operating temperature. Remove the plugs (B) and allow the excessive grease to flow out. After the grease stops flowing replace the plugs. WARNING. Use extreme caution when removing plugs from a hot pump. Very hot grease may splatter and burn any exposed skin. Because the discharge end bearing housing is pressurized, a different lubrication method is required. With a hand gun, use approximately four to six strokes in each bearing fitting (A) for the 150, 200, and 250 mm size pumps, and approximately eight to twelve strokes for the 300 mm pump. This should be done with the pump running. Wote the operating temperature of the bearing housing before and after lubrication. A sustained drop in temperature could indicate that insufficient lubricant was present before the addition of grease. A noticeable rise in temperature after several minutes could indicate excess grease in the cavity. In that case, shut off the system and pump, remove the discharge bearing cover (D), remove the excess grease, and inspect the condition of the grease and the balls of the bearing. Also, if overlubrication appears to be the problem, adjust the lubrication amount or interval accordingly. Sheet 9 of 34WARNING. Do not attempt to remove any fittings or disassemble the dis- charge end housings in any way while they are pressurized! When installing bearings that are not prelubricated, pack each bearing thoroughly with grease between balls and races. Prelubricated bearings do not require any additional grease between balls and races. SEALS ‘The lip seal arrangement located in the bearing housing supports at both ends of the pump (figures 2a, 2b, 2c, and 3a, 3b, 3c) requires the same type lubri- cant as the bearings. Grease the seals with the pump operating. We recommend that pumps operating continuously twenty-four hours a day be relubricated daily. Insert the grease through fitting (C) with a hand gun, using approxi- mately one to two strokes. Any excess seal grease will purge out through the outermost lip seal. On the drive end this grease will fall through the opening in the housing, but it will collect inside the housing on the discharge end. It is good practice to renove this excess grease whenever the discharge end bearing housing is removed, for whatever reason. The utmost care should be taken to prevent contamination of lubricant in storage and when transferring lubricant to the pressure gun. Wipe off all pressure fittings before applying the gun. ELAPPER VALVE SHAFT The grease fitting provided for lubrication of the flapper valve lever shaft should be given lubrication daily. The use of a centralized lubrication system on Fuller-Kinyon pump is not recommended. Excessive heat may result due to possible over- lubrication. Sheet 10 of 34Type M Pumps Sheet 11 of 34Figure 2b 250 mm Type M Pump woyrmans Figure 2c 300 mm Type M Pump Sheet 12 of 34Figure 3, 150 mm and 200 mm Type M Pumps Sheet 13 of 34Figure 3b 250 mm Type M Pump Sheet 14 of 343c Figure 300 mm Type M Pump Sheet 15 of 34spug jog 03 Atddng atv prosrueW ~ Gurdra ary eBana y eanbTa NOTLO3NNOD LINGNOD YO AVL 3dId ‘OLS 42/1 wo/f JO “0 'T WMINIW V HLTA HION3 NI .0-.S1 Q339X3 OL LON ONIdId ONIL93NNOD ONIdTé 1314 Yos SNOTLaMuLSNI NOLLVIViSNi OL ¥ag3e @ s0rsl¥o/n WONT 3ates | | 1 wt O° "I WAINIW V_HLIA HLON31 NI 0-.S1 O339X3 OL 10N ONIdid SNIL93NNO3 ®t wad \G2 ONIdId YIV GTO4INVH Sheet 16 of 34spud W30G 03 ATddns atv ueta - Sutdta atv abana ey omnbyaMAINTENANCE NOTE The type "M" Fuller-Kinyon pump is a metric designed unit and requires metric tools. Before dismantling the pump for repairs of any nature, carefully study the general assembly drawing supplied with the pump. Normal maintenance on the Fuller-Kinyon pump varies with the work being done by the individual unit. PUMP SCREW The pump screw is manufactured to close dimensional tolerances with fine machined surfaces. It is dynamically balanced in two planes to reduce vi- bration and ultimately increase life. When removing or installing a new screw, handle it carefully to avoid damage to surface finishes on journals marked A and B on figure 5. Marking these fine machined surfaces can cause seal failure and possible difficulty in screw removal. The frequency of screw replacement depends on load, operating pressures, and the physical nature of the material being handled. During operation, the pump screw should never strike barrel liners, and the Fuller-Kinyon pump should not be operated in this condition. If this sit- uation exists, the pump screw may be bent and may require reconditioning or replacenent. Foreign material passing through the Fuller-Kinyon pump may cause unbalance; normally heavy pieces, such as metal, collect in the bottom of the pump hopper and no damage results nf 4 t eae g & WEAR Siseve ® ® BALANCE WEIGHTS, Figure 5 Pump Screw View’ Aa P Sheet 18 of 34PUMP SCREW REMOVAL The pump screw can be removed from either end of the pump. It is recommended that removal be from the discharge end on both direct drive and V-belt drive Pumps. However, on some V-belt drive installations it may be necessary to remove the screw from the drive end, due to space limitations. The following steps describe screw removal from the discharge end. See figures 1, 2, and 3. 1. Remove the drive guard. 2. Remove the V-belts and pump sheave or loosen the drive coupling from the screw shaft. 3. Loosen the set screws (D and E). Remove the lock collar (F) and key (6) shown on figures 3a, 3b, and 3c. 4. Remove both hopper cover plates (L, figure 1), and clean out the hopper. 5. Remove the discharge end pressurization piping and accompanying filters and dryer (figure 4 or 4a). Be careful not to lose the orifice contained in the union (figure 4a) adjacent to the pressure regulator (B). 6. Remove the bearing cover (D), cap screws (E), and bearing retainer (F, figures 2a, 2b, and 2c). Reassemble the bearing cover (D); use two bolts to retain the cover in place. This prevents the screw bushing (G) from sliding out of the seal (H) during disassembly of the bearing housing @. 7. Unbolt the bearing housing (I) from the bearing support (J, figures 2a, 2b, and 2c). Use two bolts as jack screws in the tapped holes provided in the flange. Slide the bearing housing assembly off the screw shaft. 8. Remove the bearing support using the same procedure as step 7. Attach the screw puller, furnished by Fuller, to the discharge housing and screw as shown in figure 6. Turn the hex nut to extract the screw as far as the puller allows. On direct drive pumps, support the drive coupling to prevent damage by falling. 10. Remove the screw puller. Provide movable support at the end of the screw. Use crow bars, pinch bars, or other means of leverage, to pry between the screw flights and the end of pump housing to slide the screw fron the pump. Do not pry on cast iron balance wheel! as the screw is withdrawn, reposition the moveble screw support to the approximate center of the screw or provide additional support to the drive end of the screw for removal. For screw removal from the drive end, use the following procedure. See figures 1, 2, and 3. Remove the drive guard, V-belts, and pump sheave. Sheet 19 of 342. Loosen the set screws (D and E). Remove the collar (F) and key (G), shown in figures 3a, 3b, and 3c. 3. Remove both hopper cover plates (L, figure 1) and clean out the hopper. 4. Remove the discharge end pressurization piping and accompanying filters and dryer (figure 4 or 4a). Be careful not to lose the orifice contained in the union (figure 4a) adjacent to the pressure regulator (B). 5. Remove the bearing cover (D), cap screws (E), and bearing retainer (F, figures 2a, 2b, and 2c). Reassemble the bearing cover (D), using two bolts to retain the cover in place. 6. Remove the bearing housing (H) from the bearing support (I, figures 3a, 3b, and 3c). Use two bolts as jack screws in the tapped holes provided in'the flange. NOTE Jack the bolts evenly to prevent cocking. Due to the limited length of the jack bolts, spacers must be inserted between the end of the jack bolt and the support housing (I) until the bearing housing is jacked free. Remove the bearing housing from the screw shaft. + Disconnect the air piping from its air purge hole in the bearing support (figures 3a, 3b, and 3c). Use jack bolts to remove the bearing support from the screw shaft. Provide movable support at the drive end of the screw. Insert crow bars, pinch bars, or other means of leverage through hopper openings and pry the screw out through the drive end of the hopper. Do not pry on cast iron balance wheel! Support the screw as previously described in step 10 of screw removal from the discharge end. While it is not always necessary to change the barrel bushings each time the screw is changed, a check should be made of the inside diameter of the bush- ing. If it is grooved to any extent, the bushing should be replaced. Sheet 20 of 34MOUNT PULLER FRAME TO DISCHARGE HOUSING MOUNT To DISCHARGE END OF SHAFT TIGHTEN NUT TO EXTRACT SCREW ial [P— screw PULLER ASSEMBLY Figure 6 Screw Puller BARREL BUSHING REMOVAL 1. z Remove the housings (I and J, figures 2a, 2b, and 2c) and the screw. Remove the barrel bushing retainer screws (M and N) and the four set screws (P, figure 1). Pull out the short barrel bushing (9) from the discharge end of the pump. Apply high pressure air through the set screw hole and rap the bushing sharply with a hammer until all material is blown from between the barrel and bushing, allowing the bushing to slide out freely. Barrel bushings (R and S, figure 1) are also removed from the discharge end of pump. apply high pressure air through the set screw holes and rap the bushings as explained in step 3. Use a screw jack or hydraulic jack, as shown in figure 7, and jack the bushings out through the discharge end of the pump. BARREL BUSHING REPLACEMENT 1 2 Clean barrel bushings and barrel bores thoroughly before installing bushings. Insert the soft barrel bushing (R, figure 1) into the discharge end of the pump. Insert the as-cast face end of the bushing toward the hopper end of the barrel (see figure 8). Push the bushing through the barrel until the bushing extends approximately 25 mm into the hopper. Align the ribs on the OD of the bushing to straddle the antirotation set screws (P, figure 1). Sheet 21 of 34Insert the hard barrel bushing (S, figure 1) with the slotted end of the bushing toward the discharge end of the pump. Push the bushing in until it contacts the soft bushing. Position the slot in the end of the bushing on top. Assemble the retainer bolt (N, figure 1) tightly in place. From the hopper, push both barrel bushings forward until the retaining bolt is fully engaged in the barrel bushing slot. 4. Assemble the retaining bolt (M, figure 1) tightly in place. Insert the short bushing (Q) into the housing with the slot engaging the retainer bolt (1). 5. Tighten the four set screws (P, figure 1). woo BLOCKING prac, [Steen PLATE Macnnen Face C —Ascasr Face Cast Stor Hane Busmine Quy), Figure 7 | Screw Jack Figure 8 Barrel Bushing PUMP SCREW INSTALLATION The pump screw may be installed from either end of the pump. Install the screw from the same end of pump from which it was removed. Before installing the screw, remove all burrs or foreign material which may hinder insertion. It is important that the screw journals and screw bushing bores are cleaned thoroughly prior to screw insertion. Failure to follow this suggested pre- caution may cause difficulty in removing the screw. INSTALLATION FROM DISCHARGE END Remove the key from the screw shaft and insert the screw into the pump until the screw shaft journals are visible within the pump hopper. Clean the screw shaft journals and screw bushing bore thoroughly before further insertion. Carefully push the screw all the way into position util the outside face of the discharge end balance wheel is approximately flush with the end of the discharge housing. Sheet 22 of 342. Refer to figures 2a, 2b, and 2c and proceed as follows: Clean all mating surfaces, screw journals, and screw bushing bores at the discharge end of the pump. Apply Permatex sealant 1372 to the machined faces of the bearing housing support (J) and carefully assemble it over the screw shaft and bolt it tightly in place. 3. Install the O-ring (K) on the screw shaft. 4. Apply Permatex sealant 1372 to the machined faces and assemble the bearing housing (I) over the screw shaft and bolt it tightly to the bearing housing support (J). 5. Remove the cover (D) and assemble the bearing retainer (F) with socket head cap screws (E). Tighten the cap screws with a torque wrench and torque each cap screw to the values shown below. Then assemble the bearing cover (D) with Permatex sealant between the faces. PUMP SIZE ‘TORQUE ENGLISH UNITS TORQUE METRIC UNITS 300 mm & 250 mm 1a0 ft. Ib. 25.0 kg m 200 mm ao ft. Ib. 11.0 kgm 150 mn 40 ft. Ib. 5.5 kgm 6. Assemble the key (G), lock collar (F), and tighten the set screws (D and E) shown in figures 3a, 3b, and 3c. 7. Assemble the hopper cover plates and all air purge piping with accom- panying orifice. | Assemble the pump drive. 9. Lubricate the lip seals located in the bearing housing supports as described in the lubrication instructions. INSTALLATION FROM DRIVE END 1. Tf bearing housing (1) and bearing support (J) in figures 2a, 2b, and 2c have not been removed from the pump, disassemble them before installing the screw. 2. Insert the screw into the hopper end of the pump. Push the screw through ‘the pump barrel until the balance wheel, at the discharge end of the screw, is approximately flush with the end of the discharge housing. 3. Assemble the housing to the discharge end of the pump as described in steps 2, 3, 4, and 5 of preceding instructions. 4. Refer to figure 3 and proceed as follows: Clean all mating surfaces, screw journals, and screw bushing bores at the drive end of the pump. Carefuliy assemble the bearing housing support (1) and the bearing housing assenbly (#). Sheet 23 of 345. Finish the pump assembly as described in steps 6, 7, 8, and 9 of previous instructions. BEARINGS The type M Fuller-Kinyon pump uses angular contact bearings. The bearing located at the discharge end of the pump screw is fixed and absorbs both radial and thrust loads. The bearing located at the drive end is not fixed to the screw shaft and absorbs radial load only. The 150 mm and 200 mm size pumps utilize double row angular contact bearings. The 250 mm and 300 mm size pumps utilize a duplex pair of universally flush ground angular contact bearings mounted back-to-back. BEARING REPLACEMENT To replace bearings it is not necessary to remove the pump screw from the pump. Remove the bearing housing assenblies as described in the screw removal instructions. To replace the bearing at the discharge end of pump refer to figure 2a (150 mm and 200 mn size pumps), figure 2b (250 mm pump), and figure 2c (300 mm pump). Remove the bearing cover (D). 2. Slide the bearing and screw bushing (¢) out of the bearing housing. Support the bearing on the inner race and press the screw bushing out of the bearing. 4. Before replacing the bearing, clean all parts thoroughly and pack the bearing with proper lubricant. Check the seal (H) and the seal wear sleeve (L) for wear or damage and replace them if necessary. ‘The seal (i) is assembled as shown in Figure 2a, 2b, and 2c. 5. Assemble the bearing on the screw bushing (6). The 250 mm and 300 mn size pumps use a duplex pair of angular contact bearings mounted back-to-back. Bearings have either the word "THRUST" or ‘SUPPORT! stamped on one face of the outer ring. Assenble the bearings with the thrust faces together. The bearings on 300 mm pump have, in addition to the stamping, four lubrication slots in the thrust face of the outer ring. For 150 mm and 200 mm size pumps, assemble the bearing on the screw bushing with the filling notch side of the bearing in towards the shoulder on the screw bushing as shown in figure 2a. 6. Slide the bearing and screw bushing assembly into the bearing housing. Sheet 24 of 34CAUTION Do not push the screw bushing through the seal. This could damage the seal. Make a sleeve out of shim stock and assenble it through the seal and over the screw bushing, see figure 9. Push the bearing assembly into position and remove the shim stock. 7. Assemble the bearing cover with two bolts to hold the bearing in place 8. Attach the bearing housing assembly to the pump as described in pump screw installation instructions. BEARING REPLACEMENT DRIVE END OF PUMP Refer to figure 3a (150 mm and 200 mm size pumps), figure 3b (250 mm pump), and figure 3c (300 mm pump). For the 150 mm and 200 mm size pumps, assemble the bearing on the screw bushing with the filling notch side of the bearing out towards the bearing locknut. The procedure for replacing this bearing is the same as previously described for the discharge end bearing except that the bearing is retained on the screw bushing (K) by a locknut (L) and lockwasher (#). It is most important that the locknut (L) is securely tightened to firmly clamp the inner race of the bearing to the screw bushing (Kk). To facilitate tightening of the locknut (L), wrench slots are provided on the screw bushing (K). Using a spanner wrench to hold the screw bushing and to turn the locknut, tighten the locknut firmly by manual force. Then with a hanmer driving the spanner wrench, tighten the locknut firmly. Bend a washer tab into a nut slot to retain the locknut in position. The firm clamping of the bearings to the screw bushing prevents rotation of bearing on the screw bushing and establishes proper bearing pre-load for the Duplex bearings furnished with the 250 mm and 300 mm size pumps. Failure to obtain sufficient clamping of the bearings may cause bearing and seal failures. There are two lip seals (N and 0) which are assembled as shown in figure 3a, 3b, and 3c Assembly of the screw bushing into these seals should be performed with caution, utilizing the same procedure as shown in figure 9 Sheet 25 of 34'SHIM STOCK SEAL Figure 9 Bushing & Seal Assembly SEAL REPLACEMENT At each end of the pump screw, there is a material seal arrangement housed in the bearing housing support. This seal arrangement is identical at both ends; refer to figures 2a, 2b, 2c, 3a, 3b, and 3c. This seal arrangement consists of three lip seals (P) and a grease ring spacer (Q). A seal failure on the drive end would be apparent by dusting to atmosphere. On the discharge end of the pump, if seal failure should occur, no visible dusting will appear because of the pressure tight enclosure. Therefore, it is suggested that the following be performed to check seal condition: a With the pump and discharge end purge air Off, remove the pipe plug on the side of the bearing housing support (J) (figures 2a, 2b, and 2c). “Allow the purge air;to'flow so that air blows through the opening, which is~ now “wRplugged:~ This may require operation of the conveying compressors for a brief time for pumps not utilizing plant air purge to the seals. Any evidence of process material in this cavity indicates the potential for worn seals. If material is found, or if any doubt remains, proceed to step 2. In any case, shut off the purge air and replace the pipe plug. Sheet 26 of 342. Again with the pump and purge air off, remove the nipple and cap (R) found under the bearing housing support (J). Remove as mich grease as possible and inspect it for material contamination. This may be more easily accomplished with the pump warm. If no contamination is found, the seals are still satisfactory. If contaminated, the housings should be removed as previously described in the screw removal instructions, and the seals replaced as described below. A thorough inspection of the bearing and bearing lip seal is in order at this time. If any material is found in the bearing or its lubricant, or if the lip seal (H) is worn, the bearing should be thoroughly flushed and either replaced with a new bearing or repacked and reinstalled. In any case, remove all old lubricant in the bearing housing. Replace the lip seal if worn. 3. A sudden rise in bearing operating temperature may also be indicative of seal failure, vhich allows bearing contamination. a hot bearing may also be caused by underlubrication or overlubrication (see sheet 9), but if seal failure is suspected, proceed with steps 1 and 2 as a check. WARNING Do not attempt to remove any fittings or disassemble the dis- charge end housings in any way while they are pressurized! Use the following procedure to replace seals: 1. Remove the bearing housing support as previously described in the screw removal instructions. 2. Using a hammer and punch, drive the seals out of the housing. 3. Clean all parts and assenble new seals as shown in figures 2a, 2b, 2c, 3a, 3b, and 3c. Pack the grease ring (Q) and the seal cavity during assembly with the same grease used for bearing and seal lubrication. This helps to insure adequate seal protection upon start-up. Thereafter, follow the instructions for greasing found in the Lubrication Section. WEAR SLEEVE REPLACEMENT There are two hard, chrome-plated, replaceable wear sleeves on the type M pump screw as shown in figure 10. These sleeves are located on the screw shaft adjacent to the balance wheels where they provide a hard, smooth journal for the pump lip seals. The sleeves are a shrink fit on the shaft. The following procedure is suggested for replacing worn or damaged sleeves SLEEVE REMOVAL Expand the sleeve by heating with a torch. Heat the sleeve rapidly, then drive off the sleeve with a hammer and cold cutter. If heat is applied too slowly, the shaft will get too hot and prevent removal of the sleeve. Sheet 27 of 34WARNING Do not apply heat to the balance wheel. Heat can build up Pressure within the balance wheel, causing it to explode SLEEVE ASSEMBLY Allow the screw shaft to cool before installing new sleeves. Heat new sleeves in oil to approximately 300°F (150°C). Slide the sleeves over the screw shaft and position them against the shaft shoulders. The drive end wear sleeve is shorter than the discharge end sleeve. the sleeves have a chamfer on the outside diameter at both ends. The end with the smaller outside diameter chamfer also has a chamfer on the inside diameter. The end with the inside diameter chamfer is assembled tovards the screw balance wheel. To obtain reasonable seal life, the outside diameter of the wear sleeve must be concentric with the bearing journals within 0.10 mm (.004") total indicator reading. “D'LENGTH OF SLEEVE BALANCE WHEELS: TOWARD BALANCE WHEEL ORIVE END WEAR SLEEVE DISCHARGE _END WEAR: “BEARING JOURNAL. SLEEVE prc JOURNALY PUMP SIZE, "haw | aten'e rom [BE Sx (NGF 1255-1 nn6TH- 2585-01 mm | Ee (2586-01 ))16771-2557.01 mm iG 2558-01 ETT 255901 Notet 300 mm A 0-OTTT OT Act Dimensions Age IN MILLIMETERS: Figure 10 Pump Screw Dimensions Sheet 28 of 34ELAPPER VALVE ASSEMBLY The flapper valve assenbly is a mechanical seal which prevents a flow of air from the mixing chamber backward through the pump. The seating surfaces of the flapper valve assembly are hard surfaced for maximum life. If these surfaces are air cut or chipped off, the flapper valve assenbly should be replaced. PUMP SCREW CONSTRUCTION ‘The pump screw consists of a solid steel shaft and flights made from rolled mild steel welded in position (see figure 5). The flights on the discharge end of the screw have peripheral hard surfacing. In addition to the peri- pheral surfacing, the screw shaft and flight faces nearest the pump discharge also have a hard surfacing layer. The hard surfacing is always applied with gas welding. Any hairline cracks which occur in this surfacing layer are not detrimental provided the hard surfacing has an excellent bond with the base metal. After the screw shaft has received flights, balance wheels, and hard sur- facing, it is placed in a lathe and straightened. The shaft is machined to accept two wear sleeves which are mounted and held in position by a press fit. ‘The flights and shaft are then ground to the finished diameter. All screws are dynamically balanced in two planes to improve bearing life and insure vibration-free pump operation. Determining the amount and location of the balancing weights is performed by a balancing machine which indicates the amount of the correction weight and its angular location. The angular loca- tion determines which balance wheel cavity is to be used, and the amount of weight determines how much lead shot is to be placed in this cavity. FULLER. INYON PUMP SCREW INSPECTION CRITERIA In many instances it will be possible for a Fuller-Kinyon pump screw to be repaired or reconditioned. The following standards will allow you to inspect your pump screw. If these criteria are carefully followed you can, in most cases, determine the screw's suitability for repair. Flights - If the flight base metal is worn under the hardfacing, either on the flight periphery or face, the flight is replaced. The thickness of the hardfacing on the periphery is approximately 7.5 mm and about 4 mm on the flight face (as shown on figure 5). Flights are replaced in one turn (360°) segnents, and no more than three flights can be replaced on the screw economically. If more flights must be replaced, the screw should be scrapped. 2. Hardfacing Application - Screws manufactured by Fuller Company are sur- faced with Colmonoy by means of gas welding. If hard surfacing is applied with electric welding, it will not be smooth enough on the flight faces for efficient conveying nor will it bond properly. Wear Sleeves - Two areas of the screw have a pressed on wear sleeve as shown in figure 5. A damaged sleeve must be replaced. Sheet 29 of 34TROUBLESHOOTING FULLE] INYON PUMPING SYSTEM an understanding of the Fuller-Kinyon operation is a necessary foundation for operating a Fuller-Kinyon pump system. Start-up and shutdown procedures are recommended in this operation and maintenance manual and these must be adhered to carefully. The Fuller-Kinyon system was designed for a definite material specification and the material handled must match that specification for density, sieve analysis, moisture, composition, temperature, and line length. The following troubleshooting guide should be reviewed prior to pump start-up. Potential system problems may be eliminated. A. THE PUMP DOES NOT HANDLE THE SYSTEM CAPACITY 1. Check material density and sieve analysis for proper material speci- fications, since the pump is a volumetric device and changes in either property can cause capacity problems. Coarser material feed than designed for can cause: (a) higher pump motor amps and (b) the necessity for a reduction in capacity and line pressure in order to sustain adequate conveying velocity. 2. Insure that the pump hopper extension is vented and under a slight negative pressure. 3. a. While operating, check for a good material seal at the pump @ischarge. A certain amount of material compaction is necessary in order to provide a good seal. Too little can greatly reduce pumping capacity by allowing blowback. Blowback occurs when an improper seal permits conveying air to flow back through the pump. In addition to reduced capacity, backing-up in the hopper extension and low motor amps are major symptoms. Too great a seal can cause excessive power consumption and accelerate wear of some components. b. The seal may be increased by restricting the material flow out of the discharge hole. First, move the standard weight an additional distance away from the pivot on the blowout. handle. If the operation improves, but is still not satisfactory after reaching the outermost hole, extra weight may be added if no motor load problem exists. c. If a condition of excessive motor load exists, the treatment requires reducing the discharge restriction. First, move the weight towards the blowout lever pivot, and if this does not sufficiently reduce motor load, then remove the spacer located behind the flapper valve. When reinstalling the valve, use the shorter bolts which are packaged with the screw puller. a. Generally, a combination of spacer and weight position can be found at which the pump will provide the desired capacity at the minimum required horsepower level. Sheet 30 of 344. a. Excessive air flow to the discharge end seal results in aeration of material in the pump discharge housing causing reduced capacity. On systems with plant air purge, verify that the proper size orifice is installed in the union adjacent to the pressure regulator and that the regulator setting is in accordance with that shown in figure 4a. b. Material bulk density in the pump hopper may be reduced, with a corresponding loss in capacity, if the drive end purge air is excessive. In the case of air purge from a plant air supply system, ensure that the pressure regulator setting and orifice size are in accordance with data shown in figure 4a. ¢. Systems with manifold air purge also contain an orifice at the drive end; verify its installation. Its size is the same as specified in Figure 4a. 5. Insure constant feed to the Fuller-Kinyon pump. Surging feed condition into the pump causes motor amp surges requiring reduction in feed to stay within motor limits. 6. Insure that the conveying line discharge is vented via a dust collector. Positive pressure at the conveying line discharge could result in reduced capacity. 7. Check line pressure for an abnormally high reading which would indicate that the conveying line may be obstructed, thereby causing the higher conveying pressure. See pump data sheet for anticipated system operating data. Check diversion valves in the conveying line which may not be seating properly. Check the compressor for possible restrictions to intake which will cause lower than required output volume. 10. Sloping conveying lines are not recommended and could cause con- veying problens. B. BEARING FATLURE Insure proper assembly as described in this manual and on general arrangement drawings. Do not overlubricate - high bearing temperatures and premature failure will occur. 3. Do not underlubricate - see the Lubrication section of this manual for lubrication recommendations. Use of proper lubricant is necessary - see page 8 of this manual for proper specifications. Sheet 31 of 34si a EAL FAILURE Verify the type M pump seals are installed in accordance with the instructions in this manual. Insure that newly installed type M pump seals are well lubricated prior to full load system operation. Lubricate the seals while the compressor and pump are running as described on sheet 10 of this manual. - Upon replacing seals in the type M pump, check the renewable wear sleeve that the seals run on for possible damage due to abrasion. The seal wear surface must be clean and smooth or premature seal failure will occur. Insure seal purge air piping is as shown in figure 4 or figure 4a, as appropriate, and described on sheet 4 of this manual. Also refer to A.4 of system capacity troubleshooting. Material temperature in excess of 400°F will cause seal failure. An inadequate, or interruption of, air purge caused by the following conditions can result in seal failure: In the case of air purge from the pump compressor supply, the no-load manifold pressure should be 6 to 9 psig (.56 to .63 kg/on?). A differential lower than specified will not give proper purging upon reaching operating pressures. b. In the case of air purge from a plant air supply, incorrect piping, regulator settings, or orifice sizes may not provide adequate purge air. Verify the above in figure 4a. ©. Emergency power failure, while the conveying line is under pressure, could cause seal failure. 4. Improper shutdown of conveying system (not allowing cleanout of pump hopper) can cause seal failure. e. Permitting the pump hopper to be pressurized during the shut- down period encourages material to enter seals when air purge is not operative. TYPICAL PIPING ARRANGEMENT Fulle rotary compressors are of the multivane type. Arranged in milled slots on the rotor is a series of composition blades, which are free to slide by centrifugal force against interior wall of the cylinder, as the rotor turns, forming numerous crescent-shaped cells that trap the air being con- pressed, Sheet 32 of 34Fuller® single-stage compressors, direct or V-belt driven, are available with capacities of 3000 scfm (84.5 m°/min). They are pulsation and vibration free. By eliminating the need for bulky air receivers, multiple power sources, and costly foundations, they can be located adjacent to the Fuller-Kinyon pump, thereby simplifying installation and reducing costs Grouping of several compressors to use common cooling water, drain, lubri~ cation, and power facilities is recommended. Additionally, Fuller” model BC intake filter can be used to achieve maximum filtration with minimum servicing requirements. This is a single-zone, multibag collector. 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