Dover Ebsray R75, Installation, Operation & Maintenance Instructions Manual

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6
Table 1: Torque required for bolted connections
SECTION 5 - MAINTENANCE
Failure to set the vehicle emergency
brake and chock wheels before
performing service can cause severe
personal injury or property damage.
Failure to relieve system pressure prior
to performing pump service can cause
serious personal injury or property
damage.
Systems with meters will still
be pressurized even after the hose is
emptied
Hazardous
machinery can
cause serious
personal injury.
Hazardous pressure
can cause serious
personal injury or
property damage
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death Disconnecting fluid or pressure
containment components during pump
operation can cause serious personal
injury or property damage.
Hazardous
machinery can
cause serious
personal injury.
Hazardous pressure
can cause personal
injury or property
damage
5.1 ROUTINE MAINTENANCE & INSPECTION
NOTE:
Maintenance shall be performed by qualified technicians
only, following the appropriate procedures and warnings
as presented in this manual.
Routine maintenance and inspections can be performed with the
pump ‘in-situ’, so long as complete isolation, depressurising and
purging procedures have been completed. However for
repair/overhaul, it is recommended that the pump be removed
from the installation.
The R75 ball bearings are sealed for life. As such there are NO
routine maintenance requirements.
Ebsray recommends a maximum interval of three months or 500
hours operation between routine inspections (More frequent
inspections may be necessary dependent upon usage, site
conditions, and operation). These inspections should include
(but not limited to) checking for;

Leakage from the pump,
pipework, valves etc.

Excess vibration/noise

Excessive heat from the R75 or hydraulic system.
5.2 MAINTENANCE
– REPAIR & OVERHAUL
If the pump is being sent to Ebsray for maintenance or repair the
pump must be fully flushed out. i.e. returned in the state it was
provided.
Numbers in parentheses (i.e. Cover (2)) following individual parts
indicate reference numbers specified in SECTION 6.
Steps before disassembly
1. Obtain the appropriate Work Permit if required.
2. Isolate power supply to motor
– if fitted.
3. Isolate pump from liquids in inlet and discharge lines,
depressurise and purge out any toxic, flammable, corrosive
or air hardening liquids (if present).
Once the pump is removed from the pipework, flange O-rings and
gaskets cannot be re-used.
Short video tutorials are available on the Ebsray pumps website
covering main maintenance tasks.
Tools required for maintenance:

Metric Allen key set

Metric socket drive
Allen key set

Torque wrench

Small flat head screwdriver

Short (100mm long)
piece of 1-1/4 inch
schedule 40 pipe

Soft head mallet

External circlip pliers
Before any re-assembly ensure all parts are deburred and cleaned.
All O-rings MUST be replaced when any disassembly occurs.
5.3 SPARE PARTS
When ordering spare parts, to minimise pump downtime,
ALWAYS quote the pump Serial Number located on the
nameplate of the pump or SECTION 2.3 of this publication.
NOTE:
Substitute or so-
called ‘equivalent’ spare parts are not to
be used. Safe operation and pump performance may be
severely compromised if any substitute parts are used.
The use of substitute parts may void the warranty.
5.4 INSPECTION UPON DISASSEMBLY
1. Check Impeller (3) and seal zone of the Bearing Housing
(20) for damage or wear. Replace Impeller if blades have
been damaged or wear exceeds minimum recommended
dimensions:

Minimum Impeller width is 21.70mm

Minimum outside diameter is 155.75mm.
2. Check Shaft for wear, damage or run-out. Replace as
required.
3.
Inspect both Bearings for wear. It is recommended during
major overhauls that Bearings be replaced. Ball bearings are
to be replaced after 50,000 operational hours.
4. Check Mechanical Seal components for wear or damage. It
is recommended during major overhauls that Mechanical
Seal components be replaced.
Metric
setscrew size Reference
number/s Torque required
in Nm (ft-lbs)
M12 6, 27 100 (75)
M10 100B, 103B 58 (43)
M6 99B 13 (10)
M5 57A 7 (5)