Ampco Pumps Company ZP3 130 Installation And Maintenance Manual Download Page 33 | Manualshive

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Troubleshooting

Ampco Pumps Company

Page 33

Ampco Pumps Company ZP3 Manual M-004 Rev A 10.15

Troubleshooting

Each Ampco ZP3 is assembled and tested at the factory and is designed to have trouble-free
operation. Problems may occur over the life of the pump due to system variations, standard
wear, or user error. The following table has information that may help identify and solve a
problem. For additional technical assistance, please contact Ampco with the pump’s serial
number.

Symptom

Cause

Solution

NO FLOW

(rotors are not turning)

Drive motor is not running or

connected

Check connection and power source to pump

motor drive

Keys (gear, drive shaft) are

sheared or missing

Check or replace

The pump’s drive (gearbox, belts,

transmission) is broken or slipping

Check, replace, or adjust

Pump shafts or gears are broken

Check and replace, if necessary

NO FLOW

(rotors are turning)

Rotors are turning in the wrong

direction

Check motor connections for correct hookup

(see “Pump Rotation” on page 11)

Discharge port/valve is closed or

blocked

Check and open, if necessary

Inlet port/valve is closed or

blocked

Check and open, if necessary

Pump relief valve (optional) is not

set correctly, or is held open by

foreign matter.

Check and clean, if necessary. Check

system so that unwanted debris doesn’t enter

pump

NO FLOW

(pump is not priming)

Inlet valve closed

Open valve, if necessary

Inlet line restricted or clogged

Clean lines and check system

Too much air in the inlet line

Check lines for leaks, replace gaskets or

pipes, if needed

The pump’s speed is too low

Increase speed of pump

The pump’s speed is too high

Check viscosity of product, and reduce speed

as needed

No product in the inlet lines (lines

drain or siphon when pump is off)

Foot valves or check valves may be used.

Having product in the line is necessary for the

pump to prime

Pump is air locked

Install air bleeds to the pump and lines

Pump may be worn out

Increase the pumps speed or replace worn

out rotors.

Inlet pressures too low

Check pressure required. Change, if

necessary

Differential pressure differences

not developing

Install check valves on discharge to prevent

large back pressures

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Summary of Contents for ZP3 130

Page 1: ...Ampco ZP3 Series Positive Displacement Pumps Installation and Maintenance Manual Ampco Pumps Company ZP3 Manual M 004 Rev A 10 15 ...

Page 2: ... and Gauges 10 Base Alignment 10 Pump Rotation 11 Seal Flush 11 Maintenance 12 Maintenance 12 Pump Lubrication 12 Preventive Maintenance Inspection 13 Gear and Bearing Inspection 14 Annual Maintenance 15 Cleaning 15 Pump Disassembly 16 Single Seal Maintenance 17 Double Seal Maintenance 20 Disassembly 20 Assembly 20 Seal Cutaways 21 Pump Clearances 22 Pump Assembly 23 Exploded View 24 Gear Case Mai...

Page 3: ...nd shipped ready for use Standard maintenance practices are outlined in this manual For more information please refer to the Maintenance section starting on page 12 Following these guidelines will provide long lasting trouble free service when the pump s is incorporated in a properly designed system If deemed necessary to return a product under warranty or for any other reason contact Ampco Pumps ...

Page 4: ...on arrival remove the pump cover and inspect to ensure it is free from contaminate before turning the shafts Please make note of the pump serial number this will assist in the process of ordering replacement parts and or a warranty claim For more information regarding shipment damage or warranty please refer to the Introduction Warranty section in this manual Safety IMPORTANT Read and understand t...

Page 5: ...ial Pressure Temperature Range Optional Connection Size Maximum Speed GPM M3 hr Gal 100 rev Liters rev PSI Bar F C in mm in mm Rev min ZP3 6 8 1 8 0 8 0 030 300 21 40 to 200 40 to 93 1 5 38 1 25 1000 ZP3 15 11 2 5 1 4 0 052 250 17 1 5 38 800 ZP3 18 20 4 5 3 0 0 108 200 14 1 5 38 2 51 700 ZP3 30 36 8 2 6 0 0 227 250 17 1 5 38 2 51 600 ZP3 45 58 13 2 10 0 0 366 450 31 2 51 600 ZP3 60 90 20 4 15 0 0 ...

Page 6: ...re proper warning to users Do not remove these labels doing so may result in injury The pump is installed with simple but effective labels to help the customer better understand the ZP3 pump An identification plate is applied at the factory to help track the life of the pump The customer should be aware of the pump s serial number and model number prior to contacting Ampco Pumps with any concerns ...

Page 7: ...onsist of permanently fixed bases bases with leveling and or vibration isolation pads bases with attached adjustable legs or portable wheeled bases All base arrangements must be level during operation Standard base configurations base pump coupling coupling guard gear reducer and motor can be seen below in Figure 4 Permanently Fixed Leveling Isolation Pads Adjustable Legs Portable Wheeled Figure 4...

Page 8: ... Examples of such supports can be seen in Figure 5 Figure 5 Piping Support Example It is not recommended to weld custom fittings outside the factory Shrinkage and warpage can occur to the pump housing which will affect the life and performance of the pump To prevent air pockets from entering the pump from the inlet install the pump below the supply Figure 6 This will create a constant supply of pr...

Page 9: ...uction to continue while maintenance is performed on the down pump Isolation valves may also be used on both the inlet and discharge sides of the pump to shut down the flow of product to the pump This will allow for maintenance and removal of the pump without draining the entire system and risking the loss of product CAUTION Ampco s ZP positive displacement pumps are designed with extremely tight ...

Page 10: ... Ampco s factory are aligned prior to shipment Assemblies must be checked once they are installed and prior to operation Misalignment may cause unnecessary wear and shorten the life of the pump If couplings are not specified Ampco will use a flexible coupling which permits minor compensation for alignment and endplay To check the coupling alignment start with checking the angular alignment by meas...

Page 11: ...aft Seal Flush For pumps with double seals connect seal flushing before operation Operation of the pump without proper flushing will damage seal faces Flushing connections are typically 1 8 female NPT with one side being the inlet and the other the discharge Flush from the bottom to the top using the lower connection as the inlet and the upper connection as the discharge This ensures that air is r...

Page 12: ... bases with a gear reducer and motor please refer to the proper manufacturer manual for lubrication requirements These manuals are sent with the pump from the factory Important lubrication points can be seen in Figure 16 Figure 16 Lubrication Points Both gears and bearings are shipped factory lubricated with grease and oil The oil used to lubricate the gears should be changed every 500 hours with ...

Page 13: ...o metal contact between the rotors Measure the clearance between the rotor tips as seen in Figure 17 The clearance should be equal on both sides If contact is detected rotors may require replacement Figure 17 Clearance Between Rotor Tips Inspect the shaft shoulder and shaft keyway Figure 18 for wear and replace if necessary Figure 18 Shaft Inspection Points Inspect the rotor hub and rotor keyway F...

Page 14: ...d check for wear around the gear teeth If evidence of gear teeth wear is present replacement is recommended If gear s are loose check the shaft key and keyway either may require replacement Figure 20 Check for Gear Backlash Next check the condition of the bearings Do this by applying force in an up and down motion by hand on both shafts Figure 21 Also check for any horizontal movement by pushing a...

Page 15: ...igned and manufactured to be acceptable by 3A Sanitary Standards The body rotors and seals can be easily disassembled and cleaned simply by removing the cover and rotor nuts Pump disassembly information begins on page 16 Once the fluid end is disassembled follow standard practices for cleaning the product being pumped If for any reason the rotor o ring should fail and the internal threads of the r...

Page 16: ...ellville washer and retaining o ring Figure 24 Rotor Removal 3 Remove the rotors by orientating them perpendicular to each other and then pulling them out It is important to be cautious with the rotors so that they are not damaged in any way If rotors are difficult to remove use a nylon or wood lever to pry them out without damaging the body or the rotors Use Figure 25 to ensure that all parts are...

Page 17: ...seal with the pins inside the hub Press the stationary seal into the hub until is seats on the spring there should be noticeable spring resistance when pushing on the seal 4 Remove the two body hold down bolts us ing the appropriate driver Pull the pump body off by sliding it along the studs Figure 26 If the body is stuck use a soft mallet to tap the body Inspect the body for excessive wear clean ...

Page 18: ...0 making sure to align the slots on the seal to the drive pins in the rotor Press the seal down until it seats inside of the rotor 5 Slide the rotors onto the shafts until they seat against the shaft shoulder Figure 31 Ampco Pumps Company ZP3 Manual M 004 Rev A 10 15 Page 18 Figure 29 Installing the Rotating O ring 1 2 Figure 30 Inserting Rotating O ring Rotating Seal O ring Rotating Seal Align Fi...

Page 19: ...in Figure 33 and Always tighten the first rotor positioned under the overlap of the opposing rotor Repeat with the second rotor in the same orientation 8 Install a new cover o ring and slide the cover over the studs making sure that the dowels in the body are aligned with the correct dowel holes in the cover Figure 34 Visually inspect to ensure that the cover o ring remained in place Turn the cove...

Page 20: ... shoulder making sure to align the drive flats on seal seat and shaft Figure 36 Figure 36 Aligning Flats Apply a light film of lubricant to NEW inner stationary o rings and install them on the inner stationary seals Place the inner wave spring into the body and install the inner stationary seal into the seal groove Figure 37 Make sure the seal stop pins are aligned with the notches on the inner st...

Page 21: ...ith double seals connect seal flushing before operation Operation of the pump without proper flushing will damage seal faces Flushing con nections are typically 1 8 female NPT with one side being the inlet and the other the discharge Flush from the bottom to the top using the lower connection as the inlet and the upper connection as the dis charge This ensures that air is removed from the flush li...

Page 22: ... should be in accordance to Table 4 Use shims and a depth micrometer to measure the clearances Figure 39 Critical Pump Clearances Table 4 Critical Pump Clearance Dimensions Standard Rotors A Backface Clearance B Rotor to Body Clearance C Front Face Clearance Note For non standard rotors contact Ampco A Backface Clearance B Rotor to Body Clearance ZP3 Model Inch mm Inch mm Inch mm 6 15 18 002 05 00...

Page 23: ...e Bellville washer in the rotor nut and hold it in place using the small retaining o ring Figure 41 B Place one nut on at a time tightening them down using the appropriate wrench and a non metallic wedge to hold the rotor in place Figure 41 C See Table 5 for required torque values Repeat with the second rotor Figure 41 Installing and Securing the Rotor 3 Install the new cover o ring and slide the ...

Page 24: ...Figure 43 Ampco Pumps Company ZP3 Manual M 004 Rev A 10 15 ...

Page 25: ...44 If the cover is stuck use a soft mallet to tap around the edges until it breaks free Using a straight edge remove the liquid gasket used to seal the cover to the gear case Remove and discard the oil seal from the cover using an arbor press Figure 44 Gear Case Disassembly Gear Case Cover 2 Using a hammer and a punch bend the tabs straight on the lock washers Figure 45 Use a wedge wood or plastic...

Page 26: ...Once the protective block is in place push the shafts out of the gear case Reference Table 6 for the required force in tons needed to press the shafts out of the gear case Table 6 Required Force to Remove Install shafts 5 Remove all the shaft shims from the gear case and label which shaft and bore they came from If the shafts are to be reused they will need to be reinstalled with the original shim...

Page 27: ...h Place the front bearing over the shaft along with the bearing spacer Figure 51 Drawing 2 Make sure the bearing and spacer are aligned before pressing them on Reference Table 5 for the required force in tons needed to press the bearings on to the shafts Using a sleeve that rests on the bearing spacer and rides over the shaft press the bearing on until it seats against the shaft shoulder A shim ca...

Page 28: ...ss the bearing onto the shaft Using a sleeve that rests on the inner cone of the bearing and rides over the shaft press the bearing on until it seats against the spacer Make sure the bearing is rested on the bearing spacer using a shim Figure 52 Drawing 3 Figure 52 Pressing Rear Bearing onto Shaft 3 Shims located on the shaft behind the front bearing control the backface clearance of the pump the ...

Page 29: ...ure 54 Pressing Shafts into Gear Case 5 Once the shafts are pressed into the gear case install the bearing retainers to hold the shafts in place temporarily do not install liquid sealant Ensure there is proper clearance between the retainer and the gear case as seen in Figure 55 Place the body on the gear case making sure it is seated correctly Assemble the rotors into the body and tighten down us...

Page 30: ...Retainer Installation 7 Apply a light film of lubricant to the inside and outside diameters of the rear oil seals and install them into the back of the gear case with the spring side facing outward toward the gear Install the gear spacers onto the shaft and place the gear keys into the shaft key slots Figure 58 Figure 58 Rear Oil Seal and Gear Key Installation 8 Once the gear keys are installed or...

Page 31: ... oil seal Using a press install the oil seal into the back cover so that it is flush with the outside of the back cover and the spring is facing the gears Apply a silicone sealant to the edges on the back of the gear case making sure there are no gaps Slide the back cover onto the gear case making sure that the shaft is centered on the oil seal and secure it with the retaining bolts Figure 62 It i...

Page 32: ...heating or cooling fluid to be circulated through to match the demands of certain products This fluid media can preheat or cool the fluid end and sustain the product temperature during operation and short shut downs The jacketed cover is not a heat exchanger and is not designed to primarily control the product temperature This option requires longer gear case mounting studs Please contact Ampco Pu...

Page 33: ...tation on page 11 Discharge port valve is closed or blocked Check and open if necessary Inlet port valve is closed or blocked Check and open if necessary Pump relief valve optional is not set correctly or is held open by foreign matter Check and clean if necessary Check system so that unwanted debris doesn t enter pump NO FLOW pump is not priming Inlet valve closed Open valve if necessary Inlet li...

Page 34: ...ump Inlet fluid vaporization Strainers valves inlet side fittings or lines are plugged or restricted Check and clean lines valves The Inlet line is too small inside diameter or long or both Increase inlet pipe size and or decrease pipe length Too many valves or fittings Reduce number of fittings or valves Valves or strainers are too small Check and change if necessary The net inlet pressure is too...

Page 35: ...res Bearings are worn Check for bearing movement page 14 and replace if necessary Noisy Operation rotor to rotor contact Gears are loose or incorrectly timed damage to rotor may be severe Rebuild pump with new parts Keys are sheared Inspect and rebuild if necessary Gears are worn Inspect and replace gears if needed Inspect damage to rotors and rebuild if necessary Noisy Operation external mechanic...

Page 36: ... up to four times This process returns a used pump to new pump performance and appearance Each fully remanufactured pump includes a one year warranty The following upgrades are included when remanufacturing a competitor s pump 17 4 shafts stainless steel bearing retainers helical gears and sealed clean out plugs These upgrades are standard to Ampco positive displacement new and remanufactured pump...

Page 37: ...d with the pump s installation and maintenance manual 2 ATEX certified pumps will be sent with black plugs on all drain and level ports at the rear of the gear case 3 ATEX approval becomes void if non Ampco replacement parts are used in the pump For additional support regarding ATEX certification please contact the Engineering Department at Ampco Pumps Company 414 643 1852 ...

Page 38: ...ense of Purchaser 7 LOSS DAMAGE OR DELAY Seller will not be liable for loss damage or delay resulting from causes beyond its reasonable control including without limitation strikes or labor difficulties lockouts acts or omissions of any governmental authority or Seller insurrection or riot war fires floods Acts of God breakdown of essential machinery accidents embargoes cargo or material shortages...

Page 39: ...ES TO PROPERTY OTHER THAN THE PRODUCTS PURCHASED FROM SELLER c FROM ANY BREACH OF ITS WARRANTY OR ANY OTHER OBLIGATIONS TO BUYER OR d FOR ANY OTHER CAUSE WHATSOEVER WHETHER BASED ON WARRANTY EXPRESSED OR IMPLIED OR OTHERWISE BASED ON CONTRACT OR ON TORT OR OTHER THEORY OF LIABILITY AND REGARDLESS OF ANY ADVICE OR REPRESENTATIONS WHETHER OR NOT IN WRITING THAT MAY HAVE BEEN RENDERED BY SELLER CONCE...

Page 40: ...commercial export packaging which may vary depending on whether shipment is made by air land or sea Except as otherwise provided expressly stated in the agreement Purchaser will bear any additional expenses required to satisfy Purchaser s packaging requirements Packages will be marked in accordance with Purchaser s instructions if any Seller shall furnish packing lists and such other information a...

Page 41: ...a replacement order 15 Standard parts with a replacement order 5 Standard parts without a replacement order 10 Additional restocking charges may be assessed for any of the following circumstances 1 Special order motors and seals are not returnable unless we have a use for them Credit will be determined on a case by case basis 2 Impellers that are trimmed to a diameter that we don t regularly use a...

Page 42: ...209 Phone 800 737 8671 or 414 643 1852 Fax 414 643 4452 Email ampcocs ampcopumps com For additional information on the ZP3 series and other Ampco Pumps products please visit our website www ampcopumps com Ampco Pumps Company ZP3 Manual M 004 Rev A 10 15 ...

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