Johnson Pump Top Wing Series Manual Download Page 1

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A.0500.301.A-C – IM-TW/10.00 BU/GB (0401)

A-C – General, Technical,

Disassembly & Assembly

TopWing

Rotary Lobe Pumps

Summary of Contents for Top Wing Series

Page 1: ...A 0500 301 A C IM TW 10 00 BU GB 0401 A C General Technical Disassembly Assembly TopWing Rotary Lobe Pumps ...

Page 2: ... 0343 TW3 0537 TW3 1100 TW4 1629 TW4 3257 are in conformity with EC s Machinery Directive 98 37 EC Annex I Manufacturer Declaration as per EC s Machinery Directive 98 37 EC Annex 2B The product must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the Directive Örebro Sweden 1 January 2004 Anders Larsson Managing...

Page 3: ...principle 12 2 2 Operating parameters 12 2 3 System design and installation 13 2 3 1 Installations with CIP systems Cleaning In Place 15 2 3 2 Installations with SIP systems Sterilising In Place 15 2 4 Start 15 2 5 Shutdown 16 2 6 Routine maintenance 16 2 7 Trouble shooting chart 17 2 8 Heating and cooling jackets 18 3 0 Technical data 19 3 1 Rotor clearances for 150 C 19 3 2 Oil volume in gearbox...

Page 4: ... bearing arrangement 39 4 7 3 Assembly of shafts in the rotor case and setting of the tapered roller bearings 41 4 7 4 Axial adjustment of the rotors 42 4 7 5 Assembly of gears 43 4 7 6 Synchronization of the rotors 44 4 7 6 1 Manual synchronization 44 4 7 6 2 Synchronization with special tools 44 4 7 7 Assembly of end cover 45 4 7 8 Assembly of seals 46 4 7 8 1 Single mechanical seal 46 4 7 8 2 S...

Page 5: ...In case of damage clearly mark upon the carrier s paperwork with a brief description of the damage that the goods have been received in a damaged condition Notify your Johnson Pump distributor Always state the pump model and serial number when asking for assistance This information can be obtained from the name plate which is located on the end cover see section 1 5 Should the name plate be unread...

Page 6: ...tem or the drive to prevent the pump from exceeding maximum allowable pressure The safeguard system must be configured to handle reverse flow where applicable Do not operate the pump with a closed blocked discharge unless a safety relief valve is incorporated If an integrated safety relief valve is incorporated into the pump do not allow extended periods of recirculation through the relief valve T...

Page 7: ...en necessary personal protection against noise must be used See the curves for sound levels in Section 3 6 Avoid any contact with hot parts of the pumps or drive units which may cause personal injury If the surface temperature of the system exceeds 60 C the system must be marked with a warning sign of hot surface Operating conditions with temperature control devices jacketed electrically heated et...

Page 8: ... unit and system to be electrified which can lead to fatal injuries Electric motors must be supplied with adequate cooling ventilation Electric motors must not be enclosed in airtight cabinets hoods etc Dust liquids and gases which can cause overheating and fire must be diverted away from the motor Warning Pump units to be installed in potentially explosive environments must be fitted with an Ex c...

Page 9: ...emselves on the rotating shaft shaft coupling The pump unit is supplied with factory mounted guards with certified maximum gaps in accordance with standard EN 294 1992 Warning The coupling guard must never be removed during operation The locking safety switch must be turned to off and locked The coupling guard must always be reassembled after it has been removed Make sure to also reassemble any ex...

Page 10: ...3 0537 0 537 50 50 80 TW3 1100 1 100 80 80 100 TW4 1629 1 629 80 80 100 TW4 3257 3 257 100 100 150 5 Connection type 01 Hygienic threaded connection to DIN 11851 DIN 405 02 PN16 flanges to DIN 2633 04 Threaded connection to ISO 2853 05 Threaded connection for dairy industry BS 4825 06 SMS 1145 threaded connections 07 Clamp to ISO 2852 08 Flanges to ANSI B16 5 150 lbs 10 Gas thread ISO 7 1 11 DS 72...

Page 11: ...with flushing GB2 Single mechanical seal SiC to Carbon with flushing DW2 Double mechanical seal SiC to SiC to Carbon DB2 Double mechanical seal Carbon to SiC to Carbon O1 Single O ring seal DO2 Double O ring seal with flushing 9 Feet 1 Horizontal connections top drive 2 Horizontal connections bottom drive 3 Vertical connections right hand drive from shaft end 4 Vertical connections left hand drive...

Page 12: ...Wing pumps please contact your Johnson Pump distributor quoting the pump model and serial number This information is stated on the name plate which is attached to the rotor case If the name plate is damaged or missing the serial number is also stamped on the rotor case under the endcover Serial number Drive shaft Gear drive shaft Rotor case Retainer Bi Wing rotor Pump cover Air breather Foot Gear ...

Page 13: ...ty and pressure of the pumps is shown in the curve below this will give an overview of the application field The curves show the extreme limits but for many applications the limits are tighter and therefore when changing the operating conditions of the pump please contact your Johnson Pump distributor to ensure a safe and reliable working pump Differential pressure bar Capacity m3 h ...

Page 14: ...owards each other the volume between them decreases causing a rise in pressure opposite the discharge port This causes the media to be pressed out of the rotor case see fig e Regarding the pump standard parts see section 1 6 2 2 Operating parameters The maximum pressure and speed operating data are given in the table below In practice these performance data can be limited by the nature of the pump...

Page 15: ...om the system 3 The system design pipes and other equipment must have independant supports to avoid heavy loads on the pump In the case of pipe work or other equipment relying on the pump fixings for support there is a big risk for serious damage to the pump 4 For positive displacement pumps as TopWing it is recommended to install some safeguards for example a Built on safety relief valves b Exter...

Page 16: ...er is used on the suction pipe check pressure drop at the actual flow This is important to avoid cavitation which can damage the pump Please contact your Johnson Pump distributor if you require information on the pump or system NPSH characteristics 8 When installing a pump complete with drive motor and baseplate the following guidelines must be observed a The most suitable drive for the TopWing pu...

Page 17: ...ion 2 3 2 Installations with SIP systems Sterilising In Place TopWing pumps are capable of handling a SIP process Contact Johnson Pump for information regarding the temperatures needed for the process as temperature has an effect on the clearances in the pump Equipment components may need sterilising i e heating to high temperatures up to 140 C to kill organisms still remaining on the surface of t...

Page 18: ...uctions what so ever for the function When this has been done the operation can begin Keep a visual check on the suction and discharge pressure gauges and monitor the pump temperature and absorbed power where possible 2 5 Shutdown When shutting the pump down the valves on the suction and discharge side must be closed Following precautions must be taken The power is shut off and the starting device...

Page 19: ...on line Expel gas from suction line pump chamber Insufficient static suction head Raise product level to increase static suction head Product viscosity too high Decrease pump speed increase product temperature Product viscosity too low Increase pump speed decrease product temperature Product temperature too high Cool product pumping chamber Product temperature too low Heat product pumping chamber ...

Page 20: ...through the cover The heat is transferred to the rotor case via the contact faces between cover and rotor case The heating cooling channels in the pump cover together with the flush holes of the shaft seal are positioned in such a way that the required thermal effects on the built on safety relief valve rotor case and shaft seal are the best The pressure rating at the ports of the pump cover for h...

Page 21: ...otor rotor Pump type A mm B mm C mm D mm min max min max min max min max TW1 0041 0 080 0 105 0 04 0 12 0 05 0 12 0 05 0 14 TW1 0082 0 100 0 125 0 05 0 14 0 08 0 15 0 07 0 16 TW2 0171 0 125 0 150 0 10 0 20 0 10 0 17 0 09 0 19 TW2 0343 0 135 0 160 0 11 0 20 0 12 0 20 0 12 0 21 TW3 0537 0 150 0 175 0 12 0 23 0 12 0 22 0 13 0 23 TW3 1100 0 165 0 190 0 14 0 25 0 14 0 24 0 15 0 25 TW4 1629 0 200 0 225 ...

Page 22: ...er Example of typical oils Required characteristics Ambient Make Type Grade operating temp Shell Omala EP150 18 C to 0 C BP Energol GRXP EP220 0 C to 30 C Esso Spartan EP320 30 C to 150 C Pump Horizontal connection Vertical connection TW1 0 26 l 0 22 l TW2 0 63 l 0 40 l TW3 1 60 l 0 73 l TW4 4 00 l 1 75 l Air breather Oil level glass Horizontal Vertical 3 2 Oil volume in gearboxes ...

Page 23: ... X3CrNiMon27 5 2 EN 10088 3 1 4460 AISI 329 L X X X X 0030 Pump cover X2CrNiMo 17 12 2 EN 10088 3 1 4404 AISI 316L X X X X 0050 Drive shaft X3CrNiMon27 5 2 EN 10088 3 1 4460 AISI 329 L X X X X 0051 Lay shaft 0070 Foot GX5 CrNi19 10 EN 10213 4 1 4308 A351 CF8 X X X X 0120 End cover GX5 CrNi19 10 EN 10213 4 1 4308 A351 CF8 X X X X 0121 Bearing holder 2C45 EN 10083 1 1 1191 SAE 1045 X X X X 0172 Pres...

Page 24: ...8 10 41 38 TW3 0537 310 370 215 5 98 5 305 5 294 82 14 51 5 48 TW3 1100 310 370 215 5 98 5 305 5 294 82 14 51 5 48 TW4 1629 423 5 498 297 135 423 431 140 20 74 5 70 TW4 3257 423 5 498 297 135 423 431 140 20 74 5 70 Pump Type sp tb vb vc vd ve vf vh zc ze TW1 0041 65 5 225 110 135 10 74 15 95 187 84 5 TW1 0082 80 5 246 110 135 10 74 15 95 202 84 5 TW2 0171 91 5 322 164 5 195 10 106 20 130 264 118 T...

Page 25: ...3 5 29 177 28 6 21 5 19 80 5 246 10 74 15 174 95 150 202 TW2 0171 245 291 162 44 242 58 10 41 38 91 5 322 10 106 20 242 5 130 212 5 264 TW2 0343 245 291 162 44 242 58 10 41 38 116 353 10 106 20 242 5 130 212 5 289 TW3 0537 310 370 215 5 58 5 294 82 14 51 5 48 118 410 14 134 25 327 170 286 336 TW3 1100 310 370 215 5 58 5 294 82 14 51 5 48 148 455 14 134 25 327 170 286 366 TW4 1629 423 5 498 297 81 ...

Page 26: ...4 1629 178 210 TW4 3257 182 212 Pump type Enlarged inlet 2 zb 1 zb TW1 0041 25 40 117 125 TW1 0082 25 40 117 125 TW2 0171 40 50 139 147 TW2 0343 50 80 149 157 TW3 0537 50 80 173 181 TW3 1100 80 100 168 178 TW4 1629 80 100 210 220 TW4 3257 100 150 212 222 1 All thread connections DIN SMS DS BS ISO GAS THREAD NPT THREAD and all clamp connections ISO SMS DIN 2 All flanges DIN PN16 and ANSI class 150 ...

Page 27: ...DIN 11851 DIN 405 ISO 2853 BS 4825 SMS 1145 GAS THREAD DS 722 NPT THREAD ISO 2852 SMS 3017 DIN 32676 Clamp connections d2 d1 d2 d1 d2 d1 d2 d1 d2 d1 d2 d1 3 b b b 4 8 b b d2 d1 d2 d1 d2 d1 d2 d1 b b 3 4 4 Thread and clamp connections Dimension table see page 26 ...

Page 28: ... Rd 40x1 6 Rd 40x1 6 Rd 60x1 6 Rd 70x1 6 Rd 70x1 6 Rd 98x1 6 Rd 98x1 6 Rd 132x1 6 SMS 1145 d1 22 6 22 6 35 5 48 5 48 5 72 72 97 6 b 11 11 15 15 15 19 19 25 GAS THREAD d2 R 1 R 1 R 1 1 2 R 2 R 2 R 3 R 3 R 4 ISO 7 1 d1 22 6 22 6 37 6 48 5 48 5 72 72 97 6 b 14 14 14 14 14 20 20 20 d2 Rd 44x1 6 Rd 44x1 6 Rd 58x1 6 Rd 72x1 6 Rd 72x1 6 Rd 100x1 6 Rd 100x1 6 DS 722 d1 22 6 22 6 35 5 48 5 48 5 72 72 b 13 ...

Page 29: ...Class 150 50 8 50 8 73 92 1 92 1 127 127 157 2 ac PN16 85 85 110 125 125 160 160 180 ANSI Class 150 79 4 79 4 98 4 120 7 120 7 152 4 152 4 190 5 ad PN16 115 115 150 165 165 200 200 220 ANSI Class 150 108 108 127 152 4 152 4 190 5 190 5 228 6 nxøak PN16 4xø14 4xø14 4xø18 4xø18 4xø18 8xø18 8xø18 8xø18 ANSI Class 150 4xø15 9 4xø15 9 4xø15 9 4xø19 1 4xø19 1 4xø19 1 4xø19 1 8xø19 1 am PN16 16 16 16 18 ...

Page 30: ...ts in daN mass is kg Pump type Standard pump Vertical mounting weight weight TW1 0041 14 5 15 TW1 0082 16 5 17 TW2 0171 38 5 40 TW2 0343 44 45 5 TW3 0537 87 90 TW3 1100 101 104 TW4 1629 245 252 TW4 3257 286 293 3 5 Weights 3 5 1 Weights standard pump ...

Page 31: ...0 Max Differential pressure bar 90 88 86 84 82 80 dB A TW1 Max rpm TW2 Max rpm 0 Max Differential pressure bar 94 92 90 88 86 84 dB A 0 Max Differential pressure bar 100 98 96 94 92 90 dB A TW3 Max rpm 0 Max Differential pressure bar TW4 Max rpm 85 83 81 79 77 75 ...

Page 32: ... mm X X X X Hexagon Allen key Socket driven 10 mm X X X X Hexagon key Socket driven 13 mm X X Hexagon key Socket driven 17 mm X Hexagon key Socket driven 19 mm X X X X Hexagon key Socket driven 22 mm X X X X Hexagon key Socket driven 24 mm X Hexagon key Socket driven 30 mm X Torque wrench Adjustable up to min xx Nm X Torque wrench Adjustable up to min xx Nm X Torque wrench Adjustable up to min xx ...

Page 33: ...her when reinstalled especially the rotors shafts bearings and shims 4 3 O rings and lip seals When working with lip seals or O rings take care not to damage them as they pass over any sharp edges of splines threads etc Be sure that the O rings are not twisted in the groove when installing All O rings and sealing lips should be lightly lubricated with a suitable lubricant before fitting e g soap w...

Page 34: ...2 12 9 42 0525 Screw M10x20 DIN912 A4 41 M12x25 DIN912 A4 71 0620 Locking nut M55X2 SKF KMT11 M80X2 SKF KMT16 Locking nut Pos 0620 Tighten nut until friction torque measured on shaft specified torque See sectionn 4 7 3 TW1 Torque TW2 Torque Pos Description Dimension Nm Dimension Nm 0250 Retainer M10 X 3CrNiMoN27 5 2 22 M16 X 3CrNiMoN27 5 2 69 0450 Cap nut M8 DIN917 A4 21 M10 DIN917 A4 41 0455 Cap ...

Page 35: ...f the rotor case when removing the pump cover 0030 1 Remove the cap nuts 0450 2 Cavities are provided diagonal on the mounting surface between cover and rotor case to permit removing pump cover with aid of e g a screwdriver Check the O ring 0801 3 Lock the rotors by placing a block of soft material between the rotors 4 Unscrew retainer 0250 counter clockwise by using the retainer tool 5 Remove ret...

Page 36: ...from the rotor 2 Remove the stationary seal face together with O ring 0083 from the rotor case 3 Remove the stationary part of the seal together with the spring from the rotor case 4 Check O rings 0082 and 0083 5 Check condition of seal faces and spring 4 6 2 Disassembly of seals Only if section 4 6 1 has been completed Rotor Seal assembly ...

Page 37: ... ring 0085 spring and lip seal 0890 from the rotor case 4 Remove lip seal 0890 from the stationary part of the seal 5 Check the conditions of O rings 4 6 2 3 Double mechanical seal 1 Remove the rotating seal face and the O ring 0082 from the rotor 2 Remove the product side stationary seal face together with the O ring 0083 from the rotor case 3 Remove the stationary part of the seal together with ...

Page 38: ...ackside via the access opening in the rotor case TW2 4 On TW 1 please use special tool see section 5 7 3 Remove the O rings 0183 and 0085 from the support ring 0097 4 6 2 5 Double O ring seal 1 Remove the shaft sleeve 0130 from the shaft and O ring 0082 from the rotor 2 Remove the support ring 0097 together with O rings 0085 and 0183 from the rotor case The support ring can be pushed out from the ...

Page 39: ...rom the rotor case 7 TW1 Loosen the screws 0520 cross wise in several steps to release the locking elements 0651 from the gear 7 TW2 TW3 TW4 Loosen the screws of the locking assembly 0652 crosswise in several steps to release it from the gear The locking assembly is self releasing 8 Remove the gear 0190 together with the locking assembly 0652 from the shaft For TW1 locking elements 0651 9 Do this ...

Page 40: ...f locking nut 0620 and remove it 2 Support the bearing holder on mounting surface and press the internal ring of bearing 0701 together with the shaft and bearing 0700 out of the bearing holder Ensure that the mounting surface of the bearing holder is not damaged 3 Remove the bearing holder with external part of bearing 0701 and the external ring of bearing 0700 from the shaft 4 Remove the external...

Page 41: ...t must be in contact with the bottom surface of the rotor case Make sure that the surfaces are clean 2 Place the right foot on the rotor case and tighten with screws 0525 4 7 1 2 Assembly of lip seals 1 Fill the space between the lips with grease 2 Fit the lip seals 0885 into the rotor case The spring must point in the direction of the bearing The lip seals must be aligned with the axial surface i...

Page 42: ...al on the workbench and place the external ring of bearing 0700 and the bearing holder on the internal ring of bearing 0700 5 Heat the internal ring of bearing 0701 up to 120 C and fit the bearing on the shaft Wait until the parts are cooled down to ambient temperature 6 TW1 Place the locking washer 0630 on the shaft and screw on locking nut 0620 by hand until it makes contact with the internal ri...

Page 43: ...aces of the shaft 3 To check the friction torque and adjust the bearing setting of each shaft separately do as follows Use the torque meter wrench see picture on the hexagon bolt to turn the shaft and measure the friction torque Remove the torque meter wrench Place one rotor on the shaft Tool assembly sleeve for lip seal see chapter 5 0 Torque meter wrench only Measuring friction torque TW1 M10x20...

Page 44: ...the retainer and assemble it to the shaft 3 Tighten the retainer with specified torque to fix the rotor on the shaft see section 4 5 Tightening torque for nuts and screws 4 Measure the distance X from the front surface of the rotor to the front surface of the rotor case Determine the required thickness of the shim mm by using the following formula Min thickness of shim measured distance X min axia...

Page 45: ... tighten them with the retainers in the same way as mentioned above and check all axial clearances between rotor and pump cover 4 7 5 Assembly of gears 1 Place the gear 0190 with locking assembly 0652 locking elements 0651 for TW1 on the lay shaft 0051 2 TW1 Check if the screws of the locking elements are clean lubricate them with clean oil and fit them in place 3 Place the gear 0190 with locking ...

Page 46: ... both positions dimension X should be the same 2 Place a block of soft material between the rotors to lock them against each other 3 Tighten now the screws of the locking assembly elements in the same way as described for the lay shaft 4 Check the clearance between the rotors turn the drive shaft 180 and check the clearance in this position also In both positions dimension X should be the same 5 R...

Page 47: ...rews of the locking assembly elements in the same way as described for the lay shaft 4 7 7 Assembly of end cover 1 Fit lip seal 0880 with Locktite in end cover 0120 and place O ring 0181 on the rotor case 2 Put the end cover into position and tighten it with cap nuts 0455 3 Fill the space between the lips of the V seal 0881 with grease 4 Fit the V seal on the shaft by using the tool for the right ...

Page 48: ... the stationary seal face Place the stationary seal face with O ring into the rotor case Ensure that the pins in the stationary part of the seal are fitting into the grooves in the stationary seal face 3 Put O ring 0082 on rotating seal face Place the rotating seal face with O ring into the rotor Ensure that the pins in the rotor are fitting into the grooves of the rotating seal face Assembly tool...

Page 49: ...pin in the rotor case fits into the groove in the stationary part of the seal 3 Put O ring 0083 on the stationary seal face Place the stationary seal face with O ring into the rotor case Ensure that the pins in the stationary part of the seal are fitting into the grooves in the stationary seal face 4 Put O ring 0082 on rotating seal face Place the rotating seal face with O ring into the rotor Ensu...

Page 50: ... stationary seal face into the stationary part of the seal Place the stationary part of the seal with O rings and atmospheric side seal face into the rotor case 3 Put O ring 0083 on the product side stationary seal face Place the stationary seal face with O ring into the rotor case Ensure that the pins in the stationary part of the seal are fitting into the grooves in the stationary seal face 4 Pu...

Page 51: ...e with O ring into the rotor Ensure that the pins in the rotor are fitting into the grooves of the shaft sleeve 3 Rotor and shaft sleeve should be assembled together 4 7 8 5 Double O ring seal 1 Fit O rings 0085 and 0183 in support ring 0097 Place support ring with O rings into the rotor case Ensure that the pin in the rotor case fits into the groove in the support ring 2 Place O ring 0082 on the ...

Page 52: ...against each other by putting a block of soft material between the rotors 4 Tighten the retainers clockwise with the specified torque using the retainer tool See chapter 4 5 Tightening torque for nuts and screws 5 Check all clearances 4 7 9 2 Assembly of pump cover 1 Put the O ring 0801 into the groove in the pump cover 2 Place the pump cover on the rotor case Be sure that O ring 0801 stays in the...

Page 53: ...ered from Johnson Pump or produced in the own workshop The article numbers for ordering are indicated in the tables under each drawing picture together with the dimensions of the tool in question if applicable 5 2 Assembly tool for lip seals Place Rotor case front end Purpose For fitting the lip seal 0885 into the rotor case see section 4 7 1 2 Pump type Article number A B ØC 0 2 ØD 0 1 E 0 TW1 3 ...

Page 54: ...Purpose For fitting the shaft bearing assembly into the rotor case see section 4 7 3 Assembly sleeve TW2 TW3 and TW 4 All dimensions in mm Assembly sleeve TW1 Type Article number A B C D E F G H Ø I Ø J ØK Ø L ØM 0 1 0 1 TW1 3 94939 11 TW2 3 94940 11 85 70 45 12 1 2 2 25 18 41 46 2 53 56 TW3 3 94941 11 90 80 45 14 0 5 2 2 25 18 56 60 2 68 0 2 71 2 0 2 TW4 3 94942 11 125 108 55 15 1 2 5 2 5 30 22 7...

Page 55: ...lace Endcover rear end Purpose For fitting the axial lip seal 0881 on the drive shaft see section 4 7 7 All dimensions in mm All dimensions in mm Pump type Article number A B C Ø D Ø E Ø F TW1 3 94943 11 15 7 2 38 3 28 5 20 5 TW2 3 94944 11 16 8 3 59 5 48 5 39 5 TW3 3 94945 11 20 10 5 69 5 60 5 48 5 TW4 3 94946 11 25 12 5 97 5 89 5 74 5 Pump type Article number A B C Ø D Ø E ØF 0 1 TW1 3 94947 11 ...

Page 56: ...he shafts against each other see section 4 7 6 2 5 7 Tool for disassembly O ring seal TW1 Purpose To disassemble the support ring from the rotor case see sections 4 6 2 4 and 4 6 2 5 All dimensions in mm Pump Type Article number TW1 3 01983 01 TW2 3 01983 11 TW3 3 01983 21 TW4 3 01983 31 Pump Type Article number TW1 3 94998 11 ...

Page 57: ...8495 FRANCE Johnson Pompes Tel 33 0 1 39 20 50 00 Fax 33 0 1 39 56 54 22 GERMANY Johnson Pumpen GmbH Tel 49 0 5731 480 80 Fax 49 0 5731 414 00 ITALY Johnson Pump Italiana S r l Tel 39 039 604 14 63 Fax 39 039 604 90 97 NETHERLANDS Centrifugal Pumps Positive Displacement Pumps contact Belgium Johnson Pump B V Tel 31 0 592 37 67 67 Fax 31 0 592 37 67 60 Johnson Pump Horticulture Tel 31 0 174 51 84 1...

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Summary of Contents for Top Wing Series

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Johnson Pump Top Wing Series, Manual

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Summary of Contents for Top Wing Series

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