Professional Documents
Culture Documents
Clear Liquid Pump Manual
Clear Liquid Pump Manual
MANUAL 2686
Table of Contents
MANUAL #2686 Clear liquid style pump with single mechanical seal, Cycloseal or packing and
balance line with mounting style CC, VM, VC, VF, EM, F.
Replaces manual numbers: 1141, 2081, 2123, 2181, 2201, 2224, 2259, 2260, 2261, 2289, 2291, 2293,
2296, 2464, 2573, 2579, 2597, 2606, 2607, 2608, 2609, 2613, 2614, 2620.
WARRANTY ........................................................................................................... 1
INSTALLATION
Caution ................................................................................................................ 2
Assembly of Cornell Pump to Engines ............................................................... 4
Pump Support Requirements............................................................................... 6
Instructions for Flexible Couplings..................................................................... 7
START-UP ............................................................................................................... 9
MAINTENANCE
Dismantle General ............................................................................................... 11
Impeller Lockscrew ............................................................................................. 13
DISMANTLE & REASSEMBLE
Back Pullout Pump w/Keyed Shaft (Packg & M. Seal)............................... 14
FRAME DISMANTLE & REASSEMBLE
EM5 & F5 Grease Lubed and EM5K and F5K Oil Lubed ........................... 16
F16 and EM16 Grease Lubed and F16K Oil Lubed ..................................... 17
F18 and EM18 Grease Lubed and F18K Oil Lubed ..................................... 18
F18 and EM18 Grease Lubed & F18K Oil Lubed without Brg Spacers ...... 19
F18DB and EM18DB Grease Lubed and F18DBK Oil Lubed..................... 20
VC16 and VF16 Grease Lubed ..................................................................... 21
VC18 and VF18 Grease Lubed ..................................................................... 22
VC18 and VF18 Grease Lubed without Brg Spacers.................................... 23
Lube Instructions for Grease Frames .................................................................. 24
Lube Instructions for Oil Frames ........................................................................ 25
Pressure Testing .................................................................................................. 26
MECHANICAL SEAL INSTRUCTIONS
John Crane Type 1, Type 2 and Type 21 Single Seal ................................... 28
Mechanical Seal O-Ring Seat........................................................................ 30
Single Seal Product Flush.............................................................................. 32
Run-Dry Seal Instructions and Parts Page .................................................... 33
Packing Instructions ............................................................................................ 34
Lubrication Instructions for Motors .................................................................... 35
PARTS PAGES
Close Coupled Pumps (A17795)......................................................................... 36
Pump Ends Bearing Mounted
Cycloseal (A18286)....................................................................................... 37
Packing & Single Seal (A18287) .................................................................. 38
i
Table of Contents
Bearing Frames, General Assemblies
F5, Grease & Oil Lube (A18276).................................................................. 39
F16, Grease & Oil Lube (A18282)................................................................ 40
F18, Grease & Oil Lube (A18283)................................................................ 41
F18, Grease & Oil Lube without bearing spacer (A18284) .......................... 42
F18DB, Grease & Oil Lube (A18285) .......................................................... 43
ii
STANDARD WARRANTY
1.
LIMITED WARRANTY: Seller warrants, to its original Buyer, that goods manufactured by Seller are free from defects
in materials and workmanship and conform to the applicable Seller specifications for 24 months from date of shipment,
provided that the warranty period for DAF pumps is six months from date of shipment and the warranty period for
Liquid Overfeed Refrigerant Pumps is 36 months from date of shipment. If a failure to conform to specifications or a
defect in materials or workmanship is discovered within this period, Seller must promptly be notified in writing within
thirty (30) days, which notification, in any event must be received no later than 25 months from the date of shipment (or
seven months in the case of DAF pumps and 37 months in the case of Liquid Overfeed Refrigerant Pumps). Within a
reasonable time after such notification Seller will correct any failure to conform to specifications or any defect in
materials or workmanship, or in lieu of such repair, and at its sole option, shall replace the equipment or refund the
purchase price therefor paid by Buyer. THE ABOVE ARE THE BUYERS EXCLUSIVE REMEDIES FOR BREACH
OF WARRANTY.
Seller does not warrant: (a) defects caused by failure to provide a suitable installation environment for the product, (b)
damage caused by use of the product for purposes other than those for which it was purchased, (c) damage caused by
disasters such as fire, flood, wind, and lightning, (d) damage caused by unauthorized attachments or modification, (e)
any other abuse or misuse by the Buyer, including improper installation.
THE FOREGOING LIMITED WARRANTIES AND REMEDIES ARE IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHICH SELLER EXPRESSLY
DISCLAIMS, AND ALL OTHER REMEDIES. IN NO CASE SHALL SELLER BE LIABLE FOR ANY SPECIAL,
INCIDENTAL, OR CONSEQUENTIAL OR PUNITIVE DAMAGES BASED UPON ANY LEGAL THEORY. SUCH
DAMAGES INCLUDE, BUT ARE NOT LIMITED TO LOSS OF PROFITS, LOSS OF SAVINGS OR REVENUE,
LOSS OF USE OF THE PRODUCT OR ANY ASSOCIATED EQUIPMENT, COST OF CAPITAL, COST OF ANY
SUBSTITUTE EQUIPMENT, FACILITIES OR SERVICES, DOWNTIME, THE CLAIMS OF THIRD PARTIES
INCLUDING CUSTOMERS, INJURY TO PROPERTY AND, UNLESS PRECLUDED UNDER APPLICABLE
STATE LAW, BODILY AND PERSONAL INJURY.
If Buyer is in default (including, but not limited to, the failure by Buyer to pay all amounts due and payable to Seller)
under the Order of any other agreement between Buyer and Seller, Buyers rights under the warranty shall be suspended
during any period of such default and the original warranty period will not be extended beyond its original expiration
date despite such suspension of warranty rights.
Equipment performance is not warranted or guaranteed unless separately agreed to by Seller in accordance with its
guarantee policy. Performance curves and other information submitted to Buyer are approximate and no warranty or
guarantee shall be deemed to arise as a result of such submittal. All testing shall be done in accordance with Sellers
standard policy.
2.
RESALE PRODUCTS: Resale products are goods (that are sold with Sellers goods) which are not manufactured by
Seller and which are supplied as an accommodation to Buyer. Standard documentation shall be only as supplied by the
resale product manufacturer.
SELLER MAKES NO WARRANTY FOR RESALE PRODUCTS, EITHER EXPRESS OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE SOLE
WARRANTY SHALL BE THAT OF THE RESALE PRODUCT MANUFACTURER; OTHERWISE, RESALE
PRODUCTS ARE SOLD AS IS.
Buyer agrees that Seller shall not be liable for delays caused by resale product manufacturer. Buyer further agrees that
Buyers SOLE AND EXCLUSIVE REMEDY for Sellers breach of the stated responsibility shall be limited to the
difference between the resale product manufacturers price to Seller and Sellers price to Buyer for resale products in
such breach.
3.
EQUIPMENT RETURNS: Equipment may be returned to Seller with the prior written authorization of the Seller.
Returned equipment must be shipped PREPAID and must be tagged with a RGA Number. Equipment manufactured
to the Buyers specification will be credited only to the extent of the reuse value. Only unused and current equipment
purchased within one (1) year of return request will be considered for return. All equipment returns are subject to a
minimum 15% restocking charge.
Page 1 of 1
Updated May, 2002
Page 1
Supersedes
Nov, 03
3500-2
Feb, 05
CAUTION/WARNING PAGE
START-UP INSTRUCTIONS PAGE 3200-326
CAUTION:
WARNING:
Single port impellers (food pumps) have threaded shafts. Improper rotation will cause failure.
Never operate electric motors or pumps without protective cover, etc. Before disconnecting any
electrical wiring, shut off the main switch, or serious personal injury may result.
CAUTION:
WARNING:
If pumpage does not start immediately, no amount of additional pumping will solve the problem.
Do not run pumps equipped with mechanical seal dry.
CAUTION:
WARNING:
Do not exceed maximum recommended operating pressure for the pump. Consult factory as
needed.
Failure to follow instructions on this may damage pump or cause serious personal injury.
Do not operate pump when at test pressure.
For mechanical seal only. Do not run dry.
Lockscrew failure can damage impeller and volute. Proper torque during installation is important.
All rotating parts should be properly protected. Guards should be installed. Do not operate pumps
when the guards are removed.
Chopper impellers and cutter bars have VERY SHARP edges. DO NOT place body parts in
suction spool, pump inlet, or clean-outs at any time. Wear protective gloves when working on
chopper impellers, cutter bars, and associated components.
Do not run pump dry unless pump is equipped with Run-Dry option.
Once the rotating portion has been placed on the shaft, the rest of the installation must be made at
once.
Page 2
Supersedes
Nov, 03
3500-2
Feb, 05
DISMANTLING AND ASSEMBLING F18 AND EM18 CORNELL PUMP FRAMES PAGE
3200-821
CAUTION:
Never hammer the shaft or parts attached to the shaft or you will ruin both the shaft and the
bearings.
Never hammer the shaft or parts attached to the shaft or you will ruin both the shaft and the
bearings.
Never hammer the shaft or parts attached to the shaft or you will ruin both the shaft and the
bearings.
DISMANTLING AND ASSEMBLING F16 AND F16K CORNELL FRAME PUMPS PAGE
3200-810
CAUTION:
Never hammer the shaft or parts attached to the shaft or you will ruin both the shaft and the
bearings.
All engine driven pumps must be supported and alignment must be assured before bolting frame to
engine flywheel housing.
Do not allow compressed air to pressurize the pump or vent-off compressed air through the pump
as this may damage pump or cause serious personal injury.
Page 3
NEW PAGE
3200-12
March, 1992
Page 4
NEW PAGE
3200-12
March, 1992
Set the ring gear in place in the flywheel and bolt securely in place (see chart below for bolt requirements).
Remove rubber deflector on the drive end shaft and discard before installing drive gear.
Place the drive gear on the pump shaft. Secure the drive gear to the pump shaft. Some drive gears are supplied with a
tapered locking-type bushing. It is important that the bolts are torqued to the recommendation supplied with the bushing.
With block and tackle or hoist, maneuver unit into place on engine, being careful to mesh the drive gear in the ring gear
properly.
-- CAUTION -4.
5.
All engine-driven pumps must be supported, and alignment must be assured before bolting frame to the engine flywheel
housings.
Bolt the pump and frame securely to engine flywheel housing and support. Double check the location of the drive gear
in the ring gear and adjust if necessary (see chart below for bolt requirements).
Bolt Size
7/16 -14
3/8 - 16
Bolt Torque
50 Ft-lbs.
30 Ft-lbs.
# of Bolts
12
12
Clutch Size
6.5, 7.5
8, 10, 11.5
14
Bolt Size
5/16 - 18
3/8 - 16
1/2- 13
Bolt Torque
17 Ft-lbs
30 Ft-lbs
75 Ft-lbs
# of Bolts
6, 8
6, 8, 8
8
REMOVE
Torsional Vibration
A torsional vibration analysis is the responsibility of the packager. Engine manufacturers or specialized consulting offices can provide
this service. Cornell does not assume responsibility of torsional vibration problems of pump-engine units assembled by others (ISO
3046/V 1978(E) 4.1.1 and .2). Problems due to torsional vibration are not warrantable.
Page 5
NEW PAGE
3200-11
September, 1998
This pump is equipped with a support plate which is to be used by the customer to provide vertical
support for the pump. If desired, the customer may provide his own support and discard the support
provided. In either case, the pump must be supported.
NOTE: USE PUMP END FRAME BOLT SLOTS FOR SUPPORT ON EMS.
Page 6
Supersedes
Aug. 1985
3200-311
April, 1988
INSTRUCTIONS
ALIGNMENT OF FLEXIBLE COUPLINGS AND BELT DRIVES
It is not commercially feasible to furnish bed plates which, when placed on an uneven foundation, will not
spring and cause misalignment. It is, therefore, necessary to support them on foundations that can furnish the
required regidity.
Misalignment causes whipping of the shaft, adds thrust to bearings, leads to excessive maintenance and
potential failure of equipment. It is imperative that alignment be carefully checked prior to placing pump in
operation. This is done after securing to bed plate or foundation and making pipe connections.
Flexible couplings must permit some lateral floating of the shaft to take care of thermal expansion and so move
without excessive thrust on bearings.
Numerous types of flexible couplings are available. Some are easier to align than others, but all serve the
purpose of connecting two shafts capable of transmitting torque while allowing for minor misalignment
(angular, parallel or a combination).
DO NOT assume the word flexible means the couplings are designed for misalignment. Couplings can be lined
up by use of a straight edge, inside caliper, thickness gauge or outside caliper. The two ends of the couplings
must be concentric and the sides parallel with no angular misalignment.
INCORRECT ALIGNMENT
CORRECT ALIGNMENT
STRAIGHT EDGE
STRAIGHT EDGE
WARNING
All rotating parts should be properly protected. Guards should be installed to prevent the operator from coming
in contact with shafts, drives, or other rotating elements. Do not operate pumps when the guards are removed or
serious personal injury may result.
Page 7
Supersedes
Aug. 1985
3200-311
April, 1988
INSTRUCTIONS
BELT DRIVES
1. Use a matched set of V-Belts.
2. Clean oil and grease from sheaves.
Remove rust and burrs.
3. Slack off on take-up until belts can be placed in grooves without forcing.
4. Tighten the take-up until the belts are snug.
5. Align sheave grooves like this - - - - - - - - - - - - - - - - - - - - - - - - - - -
NOT THIS - -
NOT THIS - -
7. Run drive at full speed and adjust take-up until only slight bow appears in slack side of belts. Vertical
drives, drives with extremely short centers, and drives carrying pulsating loads must be operated tighter than
others.
Never use belt dressing.
8. Give belts a few days running time to become seated in sheave grooves, then readjust take-up.
9. Store belts in clean, cool, dark place.
WARNING
All rotating parts should be properly protected. Guards should be installed to prevent the operator from
coming in contact with shafts, drives, or other rotating elements. Do not operate pumps when the guards are
removed.
Page 8
Supersedes
Nov., 1997
3200-326
Feb., 2005
STARTUP CHECKLIST
BEFORE THE STARTUP OF ANY PUMP, A CAREFUL CHECK MUST BE MADE TO ENSURE THAT ALL IS IN ORDER
1.
2.
Make sure:
a. Belts and couplings (shaft) are properly adjusted, aligned, and guards are in place.
b. All thrust blocks and supports are adequate.
c. The pump and/or baseplate is bolted securely to a solid foundation. There must be no piping loads
on the pump casing, support suction or discharge piping, and piping must be clean and free of debris
and obstruction, gaskets in place and all joints secure.
d. That all electrical connections and electrical equipment are installed by a qualified and
licensed electrical contractor.
e. The pump rotates freely by hand. Then check the pump rotational direction with very
short on/off power pulses on the starter switch.
f. Pumps with mechanical seal must not run dry.
CAUTION
Some pumps are equipped with threaded shafts (Food pumps, etc.). Improper rotation will cause
failure and costly repairs. If you are unsure if your pump has a threaded shaft, contact factory.
Pumps with mechanical seal must not run dry unless equipped with run-dry option.
3.
Check the valves for proper position. If the system has a discharge gate valve, start with valve closed.
The speed of opening depends upon the size and length of your discharge pipe and capacity of the pump.
The valve should not be more than .25" open until the line is filled. The purpose of this procedure is to
reduce the possibility of a water hammer or shock if filling is too rapid.
4.
5.
Page 9
Supersedes
Nov., 1997
6.
3200-326
Feb., 2005
Motors
Check the power supply voltage, amperage, temperature and RPM with the motor nameplate. Review
item 2E with respect to rotation.
NOTE: Large motors must not be started and stopped more than five times per hour.
CAUTION
Whether placed inside our outside, the motor should be mounted on a base four to six inches
higher than surrounding floor level.
7.
8.
Check to make sure the screens are in place. A screen or strainer should have a free opening at least
three times the area of the suction pipe.
9.
Start the driver. If primed or filled with liquid, the pumping will start immediately.
Cornell Centrifugal Pump Priming
A centrifugal pump is primed when all the internal passages of the pump are filled with the liquid to be
pumped. Do not operate any pump without being properly primed unless it has been specifically
designed for such operation.
When the pump is primed and the unit is started, the pumpage will start to flow immediately. If it does
not, recheck the system for complete prime and possible air leaks. Correct the deficiencies and restart.
CAUTION
If the pumpage does not start immediately, no amount of additional pumping will solve the
problem.
WARNING
Do not allow compressed air to pressurize the pump or vent-off compressed air through
the pump as this may damage pump or cause serious personal injury.
Page 10
Supersedes 3200-3
July, 1965
3200-401
May, 1979
DISMANTLING METHODS
SIDE PLATE
SHAFT
METHOD
PIPE (OPTIONAL)
IMPELLER
Page 11
Supersedes 3200-3
July, 1965
3200-401
May, 1979
DISMANTLING METHODS
Page 12
Supersedes
Dec., 96
3200-14
July, 2001
Size
.38 16UNC
.50 13UNC
.62 11UNC
.75 10UNC
1.00 8UNC
1.12 7UNC
1.25 7UNC
1.50 6UNC
20 Ft-lb
40 Ft-lb
90 Ft-lb
135 Ft-lb
265 Ft-lb
360 Ft-lb
510 Ft-lb
875 Ft-lb
Lubrication
Do not lubricate impeller lockscrew or tapped hole or between the lockscrew and the impeller washer or
between the impeller washer and the impeller. Make sure parts are clean and dry; however, it is not necessary
to remove the protective coating from the screw. Lubricated bolts can be overstressed with the torques
indicated.
DO NOT USE LOCKSCREW TO INSTALL THE IMPELLER
CAUTION
Lockscrew failure can damage impeller and volute.
The impeller screw must be of the best material, properly forged and machined to rigid specifications not
available from local suppliers.
Buy only lockscrews available from Cornell to be sure of quality.
Page 13
Cornell Pump Company
Supersedes
Sept., 1997
3200-415
Aug., 1998
Dismantling
1. Remove balance line (47) if applicable.
2. Remove all capscrews from volute (2). Insert two of these screws into tapped holes in backplate (38).
Tighten screws to jack the volute free from the backplate exposing the impeller (3). Remove volute. Make
sure volute doesn=t fall onto impeller.
3. Remove impeller lockscrew (12) by breaker bar not by impact wrench. Make sure to apply steady and even
torque to break lockscrew loose. Allen head tooling to remove lockscrew should be in excellent condition.
Discard lockscrew, under emergency conditions this may not be possible. New lockscrew should be used
when possible. Remove the impeller washer (13).
4. If pump has a mechanical seal (40), remove any flush lines to seal gland (5A). Remove gland cap screws
evenly until capscrews are free of backplate. If pump has packing (10), loosen gland nuts (32).
5. Space wedges in pairs 180 apart between impeller and backplate. Be sure wedges are placed along
impeller vanes. Tap opposed wedges at the same time to force off the impeller. See page 3200-401 for
alternate method. Use extreme care to avoid damage to impeller, shaft and bearings. Completely remove
impeller and impeller key.
6. Unbolt and remove backplate from bracket (4). Remove mechanical seal (40) (see instructions).
7. Remove sleeve (15) only, if necessary. Install sleeve puller over outside diameter of sleeve and lock puller
to sleeve with set screws (see sleeve puller on page 3200-401). Remove puller and sleeve with standard
gear puller. If parts page shows an O-ring (296) in sleeve, sleeve can be pulled off by hand.
8. The suction wear ring (6) can be removed by drilling the ring longitudinally in three places to relieve
compression and collapsing the three sections together. Use care not to drill into the volute casting. Better
control is obtained if small pilot holes are first drilled and then enlarged to Acut@ the ring. This same
technique is used to remove the hub wear ring (7).
Reassemble
1. To replace sleeve (15): heat new sleeve very uniformly to about 4000 for about 10 minutes. Slide it on
the shaft quickly. However, if sleeve has on O-ring, it should not be heated. NOTE: remove burrs on shaft
around keyway before replacing sleeve.
2. Pump with mechanical seal (40): each seal has its own particular assembly procedures. Read instructions
for the particular seal type before proceeding, or damage to seal parts will result. Where applicable, follow
instructions for mechanical seal.
2a. Pump with packing (10): to repack stuffing box, remove the gland (5) and pull out the old packing. Insert
an extra sleeve in the stuffing box to insure proper alignment of new packing (10) which is then slipped into
the stuffing box ring by ring. Stagger the splits in the packing rings 1200 . To insure proper pressure on
each ring, push all the way down and tap lightly.
3. Replace backplate (38).
Page 14
Supersedes
Sept., 1997
3200-415
Aug., 1998
4. Use new gaskets (11). For emergency use, old gaskets should be moist and flat.
5. Replace impeller key (28) and impeller (3). (For solids handling pumps, install impeller shims to maintain
.030" minimum clearance between backplate and impeller backvanes.) Use long capscrew and several
washers to press on impeller (per page 3200-401). Do not use impeller lockscrew. The threads must be
long enough to enter the shaft approximately eight threads or turns by hand. This is necessary to protect the
threads in the shaft.
6. After replacing impeller, remove long capscrew and replace with proper impeller lockscrew with impeller
washer. The impeller lockscrew should always be new. See Impeller Lockscrew Instruction page for
Loctite requirements and torque requirement.
7. Replace volute, sliding it carefully over register. Bolt volute to backplate.
8. For seals, bring the gland and gasket against the face at the seal chamber and tighten the bolts evenly. For
packing, replace the packing gland.
9. Reconnect any lines that may have been removed (balance, flush, etc.).
Page 15
Supersedes
Sept., 1991
3200-459
Jan., 1999
Page16
Supersedes
Sept., 90
3200-810
April, 1992
Page 17
NEW PAGE
3200-821
Sept., 94
ASSEMBLING
1. Press the shaft bearing spacer and the drive end bearing onto the shaft. Pressure should be applied to the inner race.
Replace the lock washer and locknut.
2. Press the pump end bearing into the frame. Place a shim on the bearing and install the pump bracket. Do not include
gasket.
3. Press the frame bearing spacer in the drive end of the frame. Press the shaft in the drive end of the frame until the
bearing contact the frame bearing spacer.
4. Remove the pump bracket and shim.
5. Install the pump end lip seal(s) in the bracket as shown on the parts page. Slide the pump bracket (with gasket for oil
lubed frames) over the shaft, taking care not to damage or fold the lip seal(s). Install and tighten the capscrews.
6. Install the lip seal(s) in the bearing cover or drive end bracket as shown on the parts page. Reinstall the shims in the
drive end of the frame (if present when disassembled). If new bearings, frame, bearing cover or drive end bracket are
being installed, insert shims to maintain 0.021 maximum shaft endplay. (Axial of the bearing is approximately
.017. Shaft endplay cannot be less). Slide the bearing cover (with gasket for oil lubed frames) or drive end bracket
over the shaft. Install and tighten the capscrews.shaft endplay.
7. Install the deflector and lubricate per page 3200-901 for grease lubed frames, or page 3200-902 for oil lubed frames.
Page 18
Supersedes
Apr., 04
3200-963
Feb., 05
ASSEMBLING
1. Press the drive end bearing onto the shaft. Pressure should be applied to the inner race.
2. Press the pump end bearing into the frame. Place a shim on the bearing and install the pump bracket. Do not include
gasket.
3. Press the shaft in the drive end of the frame until the shaft shoulder contacts the inner race of the pump end bearing.
4. Remove the pump bracket and shim.
5. Install the pump end lip seal(s) in the bracket as shown on the parts page. Slide the pump bracket (with gasket for oil
lubed frames) over the shaft, taking care not to damage or fold the lip seal(s). Install and tighten the capscrews.
6. Install the lip seal(s) in the bearing cover or drive end bracket as shown on the parts page. Reinstall the shims in the
drive end of the frame (if present when disassembled). If new bearings, frame, bearing cover or drive end bracket are
being installed, insert shims to maintain 0.021 maximum shaft endplay. (Axial of the bearing is approximately
.017. Shaft endplay cannot be less). Slide the bearing cover (with gasket for oil lubed frames) or drive end bracket
over the shaft. Install and tighten the capscrews.shaft endplay.
7. Install the deflector and lubricate per page 3200-901 for grease lubed frames, or page 3200-902 for oil lubed frames.
Page 19
NEW PAGE
3200-826
Sept., 1994
7. Install the deflector and lubricate per page 3200-901 for grease lubed frames, or page 3200-902 for oil lubed frames.
Page 20
Supersedes
April, 92
3200-840
May, 1995
Page 21
Supersedes
Sept., 1994
3200-851
May, 1998
3.
Remove the capscrews from the bearing cover or drive end bracket
NOTE:
If the lip seals are to be saved, the shaft should be cleared of burrs or sharp protrusions which
would cut the seal. If the seals are removed or replaced, orient upper or drive end lip seal so that
the shell side of the lip seal faces toward the bearing. Orient the lower or pump end lip seal so
that the shell side faces away from the bearing per instructions in step 6 below.
Slide the bearing cover or drive end bracket off the shaft. Remove the capscrews from the pump
bracket. Slide the pump bracket off the shaft.
If there is a lip seal sleeve mounted on the shaft step adjacent to the pump end bearing, this will have to
be removed prior to removal and reinstallation of the pump end bearing. It can be removed by tearing
with wire cutters or by heating with a propane torch. Press the shaft out toward the drive end. The
pump end bearing remains in the frame and can now be removed. The drive end bearing is still on the
shaft. Remove the bearing locknut and washer. Remove the bearing with a bearing puller.
If the bearings are to be saved, keep them absolutely clean. If contaminated, wash only in clean fluid.
4.
CAUTION: Never hammer the shaft or parts attached to the shaft or you will ruin both the shaft and the
bearings.
ASSEMBLING
1. Press the bearing spacer and the drive end bearing onto the shaft. Pressure should be applied to the inner
race. Replace the lock washer and lock nut.
2. Press the pump end bearing into the frame. Place a shim on the bearing and install the pump bracket.
3. Place the grease shield in the slots in the frame shoulder.
4. Press the frame bearing spacer in the drive end of the frame. Press the shaft in the drive end of the
frame until the bearing contacts the bearing spacer.
5. Remove the pump bracket and shim.
6. Install the pump end lip seal in the bracket with the lip oriented to face toward the pump end bearing whe
the bracket is installed, press the lip seal into the bracket bore until the shell side is flush with the cast
surface of the bracket. Install a new lip seal sleeve on the shaft step adjacent to the pump end bearing.
Follow instructions on page 3200-891. Slide the pump bracket over the shaft taking care not to dama ge or
fold the lip seal. Install and tighten the capscrews.
7. Install the lip seal in the bearing cover or drive end bracket as shown on the parts page. Reinstall the shims
in the drive end of the frame (if present when disassembled). If new bearings, frame, bearing cover or drive
end bracket are being installed, insert shims to maintain 0.000" to 0.005" gap between bearing and bearing
cover or drive end bracket (this is not shaft end play). Slide the bearing cover or drive end bracket over the
shaft. Install and tighten the capscrews.
8. Install the deflector and lubricate per page 3200-901 for grease lubed frames.
Page 22
NEW PAGE
Feb., 05
3200-970
July, 05
2.
3.
Remove the capscrews from the bearing cover or drive end bracket
NOTE: If the lip seals are to be saved, the shaft should be cleared of burrs or sharp protrusions that
would cut the seal. If the seals are removed or replaced, orient upper or drive end lip seal so that the
shell side of the lip seal faces toward the bearing. Orient the lower or pump end lip seal so that the shell
side faces away from the bearing per instructions in step 6 below.
Slide the bearing cover or drive end bracket off the shaft. Remove the capscrews from the pump
bracket. Slide the pump bracket off the shaft.
4.
If there is a lip seal sleeve mounted on the shaft step adjacent to the pump end bearing, this will have to
be removed prior to removal and reinstallation of the pump end bearing. It can be removed by tearing
with wire cutters or by heating with a propane torch. Press the shaft out toward the drive end. The
pump end bearing remains in the frame and can now be removed. The drive end bearing is still on the
shaft. Remove the bearing with a bearing puller.
If the bearings are to be saved, keep them absolutely clean. If contaminated, wash only in clean fluid.
CAUTION: Never hammer the shaft or parts attached to the shaft or you will ruin both the shaft and the
bearings.
ASSEMBLING
1. Press the drive end bearing onto the shaft. Pressure should be applied to the inner race.
2. Press the pump end bearing into the frame. Place a shim on the bearing and install the pump bracket.
3. Place the grease shield in the slots in the frame shoulder.
4. Press the shaft in the drive end of the frame until the shaft shoulder contacts the inner race of the pump end
bearing.
5. Remove the pump bracket and shim.
6. Install the pump end lip seal in the bracket with the lip oriented to face toward the pump end bearing when
the bracket is installed, press the lip seal into the bracket bore until the shell side is flush with the cast
surface of the bracket. Install a new lip seal sleeve on the shaft step adjacent to the pump end bearing.
Follow instructions on page 3200-891. Slide the pump bracket over the shaft taking care not to damage or
fold the lip seal. Install and tighten the capscrews.
7. Install the lip seal in the bearing cover or drive end bracket as shown on the parts page. Reinstall the shims
in the drive end of the frame (if present when disassembled). If new bearings, frame, bearing cover or drive
end bracket are being installed, insert shims to maintain 0.000" to 0.005" gap between bearing and bearing
cover or drive end bracket (this is not shaft end play). Slide the bearing cover or drive end bracket over the
shaft. Install and tighten the capscrews.
8. Install the deflector and lubricate per page 3200-901 for grease lubed frames.
Cornell Pump Company
Page 23
Supersedes
Aug., 2001
3200-901
Mar., 2005
LUBRICATION INSTRUCTIONS
GREASE LUBRICATED FRAME PUMPS
If frame is oil lubricated (denoted by a K on the serial number plate and view gauge on side of frame), see
Lubrication Instructions Oil Lubricated Frame Pumps, page 3200-902.
Bearing in all frames are greased at the factory before shipment.
Lubrication requirements vary with speed, power, load, ambient temperatures, exposure to contamination and
moisture, seasonal or continuous operation and other factors. The brief recommendations which follow are
general in nature and must be coupled with good judgement and consideration of the application conditions.
For regreasing periods refer to table below. When adding grease be sure the grease and fittings are absolutely
clean.
Grease used for these bearings should be equivalent to one of the following manufacturers products:
G.E. Long Life Grease No. D682C5
Mobil Mobilux No. EP2
Shell Alvania EP2
Texaco Multifak AFB 2
To lubricate frame bearings, remove plastic cover from zerk fittings and be sure the fitting and end of grease
gun are clean. Use hand-operated grease gun only and pump a small amount of grease into each bearing cavity.
The surplus grease will go through the bearing and into the center part of the frame.
For regreasing periods and approximate quantity, refer to table below.
First determine frame size (located on serial number plate).
Example: 5HH-65B4
4NNT-VF16
10YB-F18DB
6NHTA-VC18
4RB-EM16
6-7-8-16
60B4 through 68B4
10-12
18-18D
20-24
30
2,000 hours
1,500 hours
1,000 hours
1,350 hours
2,000 hours
36 weeks
27 weeks
18 weeks
24 weeks
36 weeks
12 weeks
9 weeks
6 weeks
8 weeks
12 weeks
Approximate Amount of
Grease per Line Fitting
.5 cubic inch
2 cubic inches
3 cubic inches
4 cubic inches
Approximately
6 pumps
12 pumps
18 pumps
Page 24
Supersedes
Oct., 2004
3200-902
Mar., 2005
Lubrication Instructions
Oil Lubricated Frame Pumps
If frame is grease lubricated, see Lubrication Instructions Grease Lubricated Frame Pumps, page 3200-901.
The ball bearings are lubricated by the oil in the frame housing.
Add oil through the pipe plug opening at the top of the housing and fill to the level indicated on the side of the
housing. Be careful to keep out dirt and moisture. The oil level must be maintained; check and fill when pump
is not operating. The type and grade of oil used is very important for maintenance-free operation.
Oil used should be a turbine oil equivalent to one of the following manufacturers products:
Oil Temperature to 1500F
ISO VG32
Mobil DTE 797
Lubriplate HO-0
Chevron Turbine Oil GST 32
Shell Turbo T Oil 32
If checking oil temperature is not feasible, measure the bearing frame temperature at the drain connection.
In general, the bearing frame temperature will be approximately 100F lower than the oil temperature.
Oil recommendation is based on a minimum of 70 SSU at operating temperature.
FRAME SIZE
CAPACITY (OIL)
OIL RENEWAL
F5K
F85K/85DBK
F16K
F18K/18DBK
F12K
F24DBK
F20DBK/TBK
1 QUART
1.5 QUARTS
2 QUARTS
3 QUARTS
4 QUARTS
8 QUARTS
9 QUARTS
3-4 MONTHS
3-4 MONTHS
5-6 MONTHS
5-6 MONTHS
5-6 MONTHS
5-6 MONTHS
5-6 MONTHS
Page 25
Supersedes
March, 1990
3200-353
Feb., 2005
PRESSURE TESTING
CAUTION: DO NOT OPERATE PUMP WHEN AT TEST PRESSURE
WARNING: Failure to follow instructions may damage pump and/or result in serious personal injury.
TEST FLUID
Liquid may be pumpage or water or any liquid compatible with pump materials.
For pumps equipped with packing:
WARNING: Do not use compressed air to pressure test pump.
a. Fill pump gradually with liquid by gravity flow (10 PSI max. pressure).
b. Vent air from volute and close vent valve.
c. Raise pressure gradually to required test pressure. See Maximum Test Pressure.
d. Allow packing to leak freely (special protection of motor may be necessary).
e. If packing is tightened to reduce leakage, lubricant may be squeezed out of packing. Loss of packing
lubricant may require replacement of the packing.
Page 26
VENT ON VOLUTE
Supersedes
June, 88
3200-353
March, 1990
PRESSURE TESTING
CAUTION: DO NOT OPERATE PUMP WHEN AT TEST PRESSURE
FOR PUMPS EQUIPPED WITH DOUBLE SEAL, OUTSIDE SEAL WATER SUPPLY.
CAUTION: DO NOT RUN SEAL DRY SEE SEAL INSTRUCTIONS
A. Turn on supply water to seal chamber, close drain valve.
For pumps equipped with double seal, pumpage lubricated (from line containing filter
from volute to seal chamber).
CAUTION: DO NOT RUN SEAL DRY SEE SEAL INSTRUCTIONS
A. Open vent valve in seal gland and volute. (Horizontal pump has vent valve on volute only).
B. Open valves in line from volute to seal chamber on each side of filter.
C.
D.
E.
F.
G.
Fill pump gradually with liquid by gravity flow (10 PSI max. pressure).
Vent air from volute and close vent valve.
When liquid without bubble is flowing steadily from the vent valve on the seal gland, close vent valve.
If filter has glass or plastic bowl and test pressure is over 50 PSI, close valves on both sides of filter.
Raise pressure gradually to required test pressure. See Maximum Test Pressure.
Cornell Pump Company
Page 27
Supersedes
May, 1979
3200-630
April, 1968
BELLOWS
SPRING
STATIONARY
SEAT
SPRING HOLDER
DRIVING BAND
DISC
CARBON WASHER
SEALING FACE
The location of the mechanical seal in your pump is shown in the cross-section drawing of the pump. The
stationary seat is held in the gland. All other parts of the seal rotate with the shaft.
STARTING
The seal chamber must be full of liquid before operating the pump. If the shaft is vertical, and the seal gland
has a vent, open the manual vent until liquid comes out to be sure the chamber is full. Note: Pump equipped
with Cycloseal normally does not have a seal gland. Air does not need to be vented from the seal chamber
because the Cycloseal is self-venting.
MAINTENANCE
No maintenance is required. However, the pump should be examined at regular intervals for leakage resulting
from wear of the sealing faces. Occasionally new installations will leak for a short time. These must be
inspected daily. If the leakage does not reduce to almost zero, the assembly should be examined for proper seal
installation.
Page 28
Supersedes
May, 1979
3200-630
April, 1968
DISMANTLING THE MECHANICAL SEAL (For pumps equipped with a seal gland)
If the seal is to be removed, dismantle the flush line (if any) and balance line (if any). Remove the impeller
according to instructions on dismantling the pump. Unbolt the gland and move back on the shaft. Remove the
pump end containing the seal chamber. The rotating portion of the seal may now be seen. Remove the seal
spacer. Slide off the spring holder and spring. Lubricate the shaft and work off the balance of the rotating
portion being careful to avoid damaging the carbon washer. The rubber bellows will be firmly attached to the
shaft and considerable pressure will be required to remove it.
DISMANTLING THE MECHANICAL SEAL (For pumps equipped with Cycloseal)
In pumps equipped with the Cycloseal design, the seal is easily accessible once the impeller is removed. Once
the impeller is removed the spring and spring holder (if applicable) may be slid off the shaft. Lubricate the shaft
and work off the balance of the rotating portion being careful to avoid damaging the carbon washer. The rubber
bellows will be firmly attached to the shaft and considerable pressure will be required to remove it.
INSTALLING THE MECHANICAL SEAL
Clean all parts of the pump before starting reassembly. Special attention should be given to the gland, the seal
chamber, the flush line (if any), the balance line (if any), and holes in the hub of the impeller (if any).
Clean and lubricate the shaft.
Wipe the lapped sealing faces of the seat and the carbon washer perfectly clean. Use extreme care to avoid
marking the sealing face of the carbon washer. Slide the rotating portion of the seal, including spring and
spring holder on the shaft. Add the seal spacer (if applicable).
CAUTION
Once the rotating portion has been placed on the shaft, the rest of the installation must be made at once. Delay
may result in the rubber bellows seizing on the shaft at an improper position.
Reassemble the remainder of the pump. Bring the gland and gasket against the face at the seal chamber and
tighten the bolts evenly. Add the vent, flush line or water lines as required.
Page 29
Supersedes
June, 1982
3200-648
June, 2001
O-RING SEAT
REMOVING SEAT
If the seal is being replaced, remove gland (or backplate if stationary seat is installed in backplate rather than a
gland), and press out the stationary seat. For pumps or turbines with double seals remove the seat from the
stuffing box also. In pumps equipped with Cycloseal the gland is built into the backplate and the backplate will
need to be removed in order to press out the stationary seat.
INSTALLING SEAT
Clean all parts before starting reassembly. Oil the outer surface of the seat and the O ring with a light oil (not
grease). Place a cardboard disc on the sealing face to avoid damage. Press the seat into the gland or stuffing
box using firm steady pressure. Make sure the seat is all the way in. Slide the gland with the gasket or
backplate over the shaft. For pump with Cycloseal, install the backplate, then press the seat into the backplate.
Page 30
NEW PAGE
3200-648
June, 1982
MECHANICAL SEAL
O-Ring Seat Without Pin
(TURBINE)
O RING
REMOVING SEAT
If the seal is being replace, remove gland and press out the stationary seat. For turbines with double seals
remove the seat from the stuffing box also.
INSTALLING SEAT
Clean all parts before starting reassembly. Oil the outer surface of the seat and the O ring with a light oil (not
grease). Place a cardboard disc on the sealing face to avoid damage. Press the seat into the gland or stuffing
box using firm steady pressure. Make sure the seat is all the way in. Slide the gland with gasket over the shaft.
Page 31
Supersedes
April, 1995
3200-751
Aug., 1998
VOLUTE
DISCHARGE
ORIFICE
FLUSH LINE
SHAFT
SEAL CHAMBER
SEAL VENT
ORIFICE
FLUSH LINE
SEAL CHAMBER
SHAFT
VOLUTE
DISCHARGE
Do not restrict or stop the flow of flushing liquid. Without this flow the seal may heat up and fail rapidly.
Some installations have an orifice installed in the flush line to control the flow and the pressure in the seal
chamber.
DO NOT REMOVE OR ALTER THIS ORIFICE
Do not install a manual valve, which could inadvertently be shut off, in the flush line.
If pump is mounted vertically, vent the seal chamber completely so that liquid is at the seal face before starting
the pump.
Note: Pumps equipped with Cycloseal do not have a product flush line.
Page 32
Supersedes
Aug, 2001
3200-625
Aug, 2002
Page 33
Supersedes
Nov., 1984
3200-20.1
May, 1989
Page 34
Supersedes
June, 1985
3200-20.5
Jan., 1992
HORSEPOWER
1.5 TO 7.5
10 TO 40
50 TO 150
200+
2,000 hours
1,500 hours
1,000 hours
750 hours
8-Hour Day
36 weeks
27 weeks
18 weeks
13 weeks
24-Hour Day
12 weeks
9 weeks
6 weeks
4 weeks
Page 35
Page 36
Page 37
Page 38
Page 39
Page 40
Page 41
Page 42
Page 43
Supersedes
June, 88
3200-380
March, 1990
CAUSES
CORRECTIONS
Failure to pump
Reduced performance
Driver overloaded
Excessive noise
Overloads.
Page 44
Bearing failure.
Cooling vent plugged (roden, leaves, dirt, etc.)
Water is sucked into motor.
Misalignment.
Bent shaft.