manualshive.com logo in svg

Fristam Pumps FKL-150, Instruction And Maintenance Manual, Page: 2 / 50

Share
Download
Fristam Pumps FKL-150 Instruction And Maintenance Manual Download Page 2

Fristam Pumps

D

ESCRIPTION

This manual contains installation, operation and repair instructions for the Fristam FKL 15, 0, 5, 50, 
75, 150, 50 and 400 Series balanced circular piston pump.
The FKL pump is a positive displacement pump characterized by its balanced rotor design. The rotors 
travel through a precisely machined, close clearance channel in the housing and cover allowing the 
product to be pumped very efficiently.
The FKL series pump features a unique balanced rotor design with heavy-duty shafts allowing the 
pump to maintain its efficiency at differential pressures up to 300 psi. The pump also features rotors 
made from “non-galling” stainless steel, which allows the pump to continue to run even under extreme 
conditions.
The FKL series pump is ideal for pumping products that are shear sensitive, have a high viscosity and/
or contain large particulate. The FKL series pump excels in applications with high differential pressure 
and/or low inlet pressures and its high efficiency, low slip performance makes it an excellent pump for 
metering applications for consistent flow control.
The FKL series pump is available with any connection type desired and may be mounted with the in-
let/outlet connections in a horizontal or vertical orientation. The pump should be coupled to a motor/
drive assembly properly specified to give the desired performance for the required application.

!

  CAUTION:  BEGIN ALL PUMP MAINTENANCE OPERATIONS BY DISCONNECTING THE ENERGY 

SOURCE TO THE PUMP. OBSERVE ALL LOCK OUT/TAG OUT PROCEDURES AS 
OUTLINED BY ANSI Z44.1-198 AND OSHA 1910.147 TO PREVENT ACCIDEN-
TAL START UP AND INJURY.

Summary of Contents for FKL-150

Page 1: ...FKL Series Pump INSTRUCTION AND MAINTENANCE MANUAL FKL 25 50 75 150 250 and 400 Style Pump SANITARY POSITIVE DISPLACEMENT PUMP ...

Page 2: ...under extreme conditions The FKL series pump is ideal for pumping products that are shear sensitive have a high viscosity and or contain large particulate The FKL series pump excels in applications with high differential pressure and or low inlet pressures and its high efficiency low slip performance makes it an excellent pump for metering applications for consistent flow control The FKL series pu...

Page 3: ...eplacement FKL 25 75 150 250 400 18 23 Gearbox Disassembly 18 19 Gearbox Assembly 19 Setting the Rotor Gap 19 20 Install the Gearbox 21 22 Bearing and or Shaft Replacement FKL50 24 29 Gearbox Disassembly 24 Gearbox Assembly 25 26 Install the Gearbox 26 28 Setting the Rotor Gap 29 FKL Exploded View Drawing FKL 25 75 150 250 400 30 31 FKL Part Numbers FKL 25 75 150 250 400 32 36 FKL 50 Exploded View...

Page 4: ... Carbon standard Also available in Silicon Carbide Chrome oxide SS Rotating Seal Ring Material Chrome Oxide SS Also available in Silicon Carbide Other O rings mechanical seals Viton standard Also available in EPDM and other options available O ring Seal Type Single Double O ring Seal Material Viton standard Also available in EPDM and other availableupon request Note o ring seal not available on th...

Page 5: ... 060 7 750 Dimensions are in inches The Y dimension is shown for reference Recommended Torque Values Part FKL 25 FKL 50 FKL 75 FKL 150 FKL 250 FKL 400 Cover Nut 15 ft lb 45 ft lb Rotor Bolt 25 ft lb 50 ft lb 65 ft lb Bearing Cap Screw 60 in lb 10 ft lb 25 ft lb Bearing Lock Nut 50 ft lb 7 in lb 50 ft lb Housing Hex Head Bolt 60 in lb 10 ft lb 45 ft lb Gearbox Cover Bolt 10 ft lb 20 ft lb Mounting ...

Page 6: ...0 0051 0 0067 0 135 0 185 0 0053 0 0073 0 22 0 34 0 0087 0 0134 250 0 09 0 13 0 0035 0 0051 0 110 0 170 0 002 0 0067 0 16 0 28 0 0063 0 011 0 14 0 18 0 0055 0 0071 0 18 0 24 0 0071 0 0094 0 27 0 39 0 0106 0 0154 400 0 10 0 14 0 0039 0 0055 0 120 0 180 0 0047 0 0071 0 16 0 30 0 0063 0 0118 0 16 0 20 0 0063 0 0079 0 20 0 26 0 0079 0 0102 0 27 0 41 0 0106 0 0161 Chocolate Rotors 25 0 24 0 26 0 0094 0...

Page 7: ...p mounting to vertical the sight glass and vent cap will need to be switched Piping CAUTION Because the FKL pump is a highly efficient positive displacement pump the user needs to ensure that the pump will not be over pressurized during operation as this can cause severe damage to the pump Over pressurization can occur if a valve is closed on the discharge of the pump and the pump continues to run...

Page 8: ...lt in premature bearing failure or other damage If the pump is not shipped with a drive unit use a flexible coupling between the pump and drive unit Align the pump and drive unit according to the coupling requirements Checking alignment Remove the wire ring from the coupling sleeve and let it hang between the sleeve and one of the flanges To check the parallel alignment place a straight edge acros...

Page 9: ...lush the system 2 Make sure that the pump and drive are properly lubricated Check the lubrication section page 52 in this manual for the pump See instructions from the manufacturer for the drive 3 Check to make sure that all guards are in place and secure 4 Check for proper pump and drive rotation Figure 9 Make sure that the pump is flooded with product when checking the rotation Running the pump ...

Page 10: ...ow enough time for all of the wetted components inside the pump to reach a steady state temperature before you start the pump If your process does not allow you to stop the pump during this transition you need to install rotors that provide larger clearances Note that the clearances inside the FKL pump are extremely small Due to the use of a rotor bolt additional cleaning may be necessary if there...

Page 11: ...then remove the jacketed cover jacketed cover o ring and then continue with instructions B and C Remove the Rotors a To loosen the first rotor place the wooden dowel between the rotors as shown in Figure 10 b Turn the first rotor bolt counter clockwise with the appropriate wrench c Remove the rotor bolt and rotor cap with o rings from the first rotor d Repeat instructions a c for the second rotor ...

Page 12: ... from the pump shaft If replacing the cartridge with a new cartridge proceed to the Seal Cartridge Installation section on page 14 Disassembly of Seal Cartridge for Mechanical Seals Place all of the seal parts on a clean work area and disassemble one car tridge at a time a Place the seal cartridge with the seal face up onto the seal assem IL 0522 Figure 11 IL 0526 Figure 12 ...

Page 13: ...t a time a Lubricate the new outer stationary seal o ring and slightly stretch b Fit the outer stationary seal o ring into its groove inside the seal housing c Place the inner and outer seal springs into the seal housing d Set the seal housing on the seal assembly tool e Place the new inner stationary seal into the seal housing f Single mechanical seal Lubricate the outer edge of the single seal i...

Page 14: ...g instructions d and e g Next lubricate and install the two new rotating seal o rings into the first groove on the pump shaft as shown in Figure 16 Aseptic seal only lubricate and install the four rotating seal o rings i Finally install the two new rotating seal rings onto the shaft The rotat ing seal ring will fit into the grooves on the shaft and interlock with the shaft If you can rotate the se...

Page 15: ...now ready to install the pump housing onto the gearbox Install the pump housing while slowly rotating the shaft Pump Head Assembly Note Any debris between the gearbox and housing will affect the gap Make sure the gearbox front face and pump housing surfaces are clean a Carefully slide the pump housing over the pump shafts and onto the gearbox Make sure that the housing is positioned so that the sm...

Page 16: ...n Table A2 page 5 Verify Rotor Clearances With the rotors installed you should check the clearances around the rotor to ensure that the pump was assembled properly Use feeler gauges to verify the back and radial clearance between the rotors and the housing Use a depth micrometer to verify the front face clearance see Table A3 page 6 If the gap is incorrect please see Setting the Rotor Gap section ...

Page 17: ...Shaft Replacement for the FKL 25 75 150 250 400 Series Caution Begin all pump maintenance by discon necting the energy source to the pump Observe all lock out tag out proce dures as outlined by ANSI Z244 1 1982 and OSHA 1910 147 to prevent acci dental start up and injury For Bearing and or Shaft Replacement for the FKL 50 Series see page 24 29 Tools Required for Gearbox Disassembly Arbor press 3 8...

Page 18: ... h Loosen the bearing lock nut from both shafts using the spanner wrench i Remove the bearing lock nuts bearing lock nut washers and rotors from both pump shafts j Place the gearbox on an arbor press with the spline ends of the shafts facing down as shown in Figure 22 Press on the shafts one at a time to remove them from the gearbox Make sure to support the shafts so that they do not fall and get ...

Page 19: ...ly slide the pump housing over the pump shafts and onto the gearbox Make sure that the housing is positioned so that the small pin slides into the small bushing on the gearbox and the large pin slides into the large bushing The long housing studs will help to align the pump housing in the proper position d Secure the pump housing with the hex head housing bolts Note On the FKL 25 use six 18mm long...

Page 20: ...ou must remove This can be accomplished by removing the shims currently in the pump and using a combination of the shims that were acquired from Fristam Once you have your rotor to housing measurements you can remove the rotors pump housing and remove both pump shafts from the gearbox You will also need to remove the outer races for the front bearings to remove the current shims and replace them w...

Page 21: ...again Install the rear bearing assemblies onto each shaft Lightly grease the rear bearing step on the pump shafts a Press the rear bearing cone onto the shaft b Install the inner bearing spacer bearing cup outer spacer and the other cup Figure 30 c Press the other rear bearing cone onto the shaft Position the gearbox on the arbor press one shaft at a time to press the bearings into place Be sure t...

Page 22: ...to the torque speci fied in Table A2 page 5 h Re install the oil drain plug and vent plug onto the gear box Fill the gearbox with oil to the center of the oil sight glass Once the gearbox is assembled the pump head can be assembled pages 16 and the rotor to housing clearances can be checked Make any necessary adjustments as required Figure 30 IL 0541 Figure 29 ...

Page 23: ...p 23 IL 0528 Figure 31 PLACE DIAL INDICATOR ON THESE SURFACES TO CHECK FOR ZERO ENDPLAY ON BOTH SHAFTS PUSH AND PULL ON THIS END OF SHAFT CHECK DIAL INDICATOR FOR MOVEMENT DIAL INDICATOR 1265000025 5 14 02 Figure 32 ...

Page 24: ... start the gearbox disassembly complete the Pump Head Disassembly on pages 11 12 a Remove oil drain plug with the 3 8 Allen wrench and drain the oil b Remove the gearbox cover bolts with the 13 mm wrench and remove the gearbox cover and gearbox cover gasket c Remove the bearing cap screws with the 5 mm Allen wrench then remove the bearing caps d Remove the bearing cap o rings from both bearing cap...

Page 25: ...idle shaft first If you are not sure about shaft location the drive shaft will always be located in the same bore on the gearbox To locate the correct bore stand facing the gearbox with the gearbox cover on your left side The drive shaft will be in the top bore posi tion Assemble front bearings onto shafts Cover the coupling area of the drive shaft with tape to protect it Lightly oil the pumps sha...

Page 26: ...ew shaft and 0 020 of shim with a used shaft Install the Gearbox Lightly oil the pump shafts on the step for the gears Install the shafts one at a time into the gearbox Remember that the drive shaft will be in the top bore as seen from the pump side of the gear box with the gearbox cover on the left a Deburr and install the gear key into the shaft b Place one of the gears with the part number faci...

Page 27: ... that the part numbers on both gears face the bearing lock nut end of the gearbox This will ensure proper timing i Install the rotors onto the shafts j Place a wooden dowel between the rotors as shown in Figure 40 and tighten the bearing lock nut on the drive shaft with the spanner wrench until a rolling torque of 7 in lbs is reached Use an indicating torque wrench k Tighten the idle shaft with th...

Page 28: ...ring caps onto the gearbox Secure with the bearing cap screws and tighten to the specified torque Table A2 page 53 q Lightly oil the outside edge of the two front oil seals and press into the front bearing bores of the gearbox r Place the new gearbox cover gasket and gearbox cover on the gearbox and secure with the gearbox cover bolts Tighten to the torque specified in Table A2 page 5 s Re install...

Page 29: ... measure from the clearance value that is listed in the table This will give you the amount of shim material that you must remove This can be accomplished by removing the shims currently in the pump and using a combination of the shims that were supplied with the new shafts Once you have your rotor to housing measurements you can remove the rotors pump housing and remove both pump shafts from the ...

Page 30: ...Fristam Pumps 30 FKL 25 75 150 250 400 Exploded View 2 3 4 5 6 8 9 11 12 14 15 16 17 18 19 20 35 34 36 37 38 39 40 41 42 44 45 46 1 10 43 13 7 1265000005 Rev 1 ...

Page 31: ...FKL Series Pump 31 ...

Page 32: ...Mounting strap screw 4 1101000029 15 Housing stud long 6 1103000035 47 Gear key 2 1315000014 16 Gapping shim 0 050 4 1373000031 48 Idle shaft 1 1372600003 Gapping shim 0 020 2 1373000032 Idle shaft for o ring only 1372600015 Gapping shim 0 010 0 1373000033 49a Large mounting pin housing 1 1891000069 Gapping shim 0 002 0 1373000034 49b Large mounting pin cover 1 1891000069 17 Front bearing assembly...

Page 33: ...sing stud long 2 1103000039 46 Mounting strap screw 4 1101000033 16 Gapping shim 0 050 4 1373000027 47 Gear key 2 1315000029 Gapping shim 0 020 2 1373000028 48 Idle shaft 1 1372600011 Gapping shim 0 010 0 1373000029 Idle shaft for o ring seal 1372600017 Gapping shim 0 002 0 1373000030 49a Large mounting pin housing 1 1891000073 17 Front bearing assembly 2 1173000014 49b Large mounting pin cover 1 ...

Page 34: ...5 Housing stud long 2 1103000029 46 Mounting strap screw 4 1101000033 16 Gapping shim 0 050 4 1373000027 47 Gear key 2 1315000012 Gapping shim 0 020 2 1373000028 48 Idle shaft 1 1372600025 Gapping shim 0 010 0 1373000029 Idle shaft for o ring seal 1372600019 Gapping shim 0 002 0 1373000030 49a Large mounting pin housing 1 1891000074 17 Front bearing assembly 2 1173000016 49b Large mounting pin cov...

Page 35: ...033 15 Housing stud long 2 1103000025 47 Gear key 2 1315000024 16 Gapping shim 0 050 4 1373000023 48 Idle shaft 1 1372600005 Gapping shim 0 020 2 1373000024 Idle shaft for o ring seal 1372600021 Gapping shim 0 010 0 1373000025 49a Large mounting pin housing 1 1891000074 Gapping shim 0 002 0 1373000026 49b Large mounting pin cover 1891000074 17 Front bearing assembly 2 1173000017 50 Rotor bolt o ri...

Page 36: ...ing stud long 4 1103000031 46 Mounting strap screw 4 1101000039 16 Gapping shim 0 050 4 1373000035 47 Gear key 2 1315000027 Gapping shim 0 020 2 1373000036 48 Idle shaft 1 1372600007 Gapping shim 0 010 0 1373000037 49a Large mounting pin housing 1 1891000078 Gapping shim 0 002 0 1373000038 49b Large mounting pin cover 1 1891000077 17 Front bearing assembly 2 1173000019 50 Rotor bolt o ring viton 2...

Page 37: ...FKL Series Pump 37 ...

Page 38: ...ard 23 Small mounting pin 24 Hex head housing bolt 24A Socket head housing screw 25 Pump housing 26 Housing stud short 27 Rotor o ring 28 Rotor standard 29 Rotor cap o ring 30 Rotor cap 31 Cover o ring 32 Pump cover 33 Forcing screw 34 Gearbox cover gasket 35 Rear bearing assembly 36 Oil sight glass 37 Gearbox cover 38 Oil drain plug 39 Gearbox cover bolt 40A Gear snap ring 41 Gear 43 Bottom mount...

Page 39: ...FKL Series Pump 39 ...

Page 40: ...372600012 47 Gear key 2 1315000030 15 Housing stud long 2 1103000023 48 Idle shaft 1 1372600001 16 Gapping shim 0 050 4 1373000019 Idle shaft for o ring seal 1372600013 Gapping shim 0 020 2 1373000020 49a Large mounting pin housing 1 1891000069 Gapping shim 0 010 0 1373000021 49b Large mounting pin cover 1891000070 Gapping shim 0 002 0 1373000022 50 Rotor bolt o ring viton 2 1180000085 17 Front be...

Page 41: ...037 1820000018 1820000040 1820000022 1820000020 1820000024 59 Single stationary seal carbon 2 1815600058 1815600049 1815600060 1815600051 1815600052 1815600055 Single stationary seal Silicon carbide 1815600057 1815600050 1815600061 1815600054 1815600053 1815600056 Single stationary seal Chrome oxide SS 1815600086 1815600066 1815600112 1815600108 1815600106 1815600097 60 Seal housing screw 8 110100...

Page 42: ...2 1815600055 Single stationary seal Silicon carbide 1815600057 1815600050 1815600061 1815600054 1815600053 1815600056 Single stationary seal Chrome oxide SS 1815600086 1815600066 1815600112 1815600108 1815600106 1815600097 60 Seal housing screw 8 1101000190 1101000030 1101000034 1101000030 12 1101000034 12 1101000038 12 61 Double stationary seal o ring viton 2 1180000256 1180000186 1180000148 1180...

Page 43: ...398 Rotor bolt o ring EPDM 1180000188 1180000129 1180000399 60 Seal housing screw 8 1101000041 1101000031 1101000041 1101000203 12 1101000035 12 62 Seal housing 2 1845000012 1845000001 1845000017 1845000008 1845000003 64 Single stationary seal o ring viton 2 1180000030 1180000014 1180000253 1180000231 1180000052 Single stationary seal o ring EPDM 1180000247 1180000063 1180000278 1180000282 1180000...

Page 44: ...0190 1101000030 1101000030 12 1101000034 12 62 Seal housing 2 1845000011 1180000014 1845000016 1845000007 1845000009 64 Single stationary seal o ring viton 2 1180000030 1180000063 1180000253 1180000231 1180000052 Single stationary seal o ring EPDM 1180000247 1910000010 1180000278 1180000282 1180000219 68 Water pipe 2 1910000010 1180000293 1910000010 1910000001 69 Double seal housing o ring viton 1...

Page 45: ...T FKL Jacketed Cover Option Fristam s jacketed cover is applied directly over the existing cover It will require longer studs and forcing screws Available all models Max Pressure 100 psi Connections 1 8 NPT FKL 25 250 1 2 NPT FKL 400 Materials of Construction 304 stainless steel FKL Aseptic Option STEAM IN STEAM IN IL 0728 8 1 00 STEAM OUT STEAM OUT Seal Housing Rotating Seal Cover IL 0736 8 14 00...

Page 46: ...pping or broken necessary Coupler or gear key sheared Replace No product flow Pump rotation is incorrect Reverse rotation pump is turning Valve closed in suction line Open valve Suction line clogged or restricted Clear suction line Pump speed too slow Increase speed Suction line does not remain flooded Install foot or check valve Excessive clearances in pump Replace out of tolerance components NIP...

Page 47: ...FKL Series Pump 47 Pump Maintenance Record Date Service Performed By ...

Page 48: ...Fristam Pumps 48 Pump Maintenance Record Date Service Performed By ...

Page 49: ... by purchaser within thirty 30 days after pur chaser learns the facts upon which such claim is based Any claim not made in writing and within the time period specified above shall be deemed waived PURCHASER S SOLE AND EXCLUSIVE REMEDY AND FRISTAM PUMP S MAXIMUM LIABILITY FOR CLAIMS ARISING HEREUNDER OR FOR NEGLIGENCE FOR ANY AND ALL LOSSES AND DAMAGES RESULTING FROM ANY CAUSE SHALL BE EITHER THE R...

Page 50: ...2410 Parview Road Middleton WI 53562 2524 1 800 841 5001 608 831 5001 Website www fristam com Email fristam fristampumps com Fristam Pumps USA Limited Partnership Part 1050000038 Drawing 1250000001 Rev C Updated 2 15 08 ...

Reviews:

No comments