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Tuthill GG015, Installation And Service Instructions Manual, Page: 17 / 32

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Tuthill GG015 Installation And Service Instructions Manual Download Page 17

 

 

Service Manual 73 

Page 17 of 32 

Pump-Complete Disassembly Procedure 

 
 

!

    WARNING

 

 
Failure to follow these instructions could result in serious bodily injury or death. 
 
Do not attempt to work on any Tuthill pump installation before completing the steps below. 
 
Only authorized personnel who are familiar with the repair of mechanical products should perform 
the necessary repair work.  You must familiarize yourself with the entire contents of this manual 
prior to performing any work 
 
Disconnect the drive so that it cannot be started while work is being performed. 
 
Review the Material Safety Data Sheet (MSDS) applicable to the liquid being pumped to 
determine its characteristics and the precautions necessary to ensure safe handling. 
 
Vent all pressure within the pump through the suction or discharge lines. 
 
Ensure that the pump has cooled a safe temperature prior to performing any work on the pump. 
 

 

 

REMOVE THE PUMP FROM BASE:

 

 
The pump can be removed from the base for service or it can be disassembled without 
disturbing the housing, provided a spacer coupling was originally installed. 
 

IF NECESSARY, REMOVE SAFETY RELIEF VALVE:

 

 
If the pump has a safety relief valve mounted on it, remove it by loosening the bolts that 
mount it to the cover or housing. 

 

REMOVE PUMP COVER: 

 
Note: On pumps with relief valves on the cover, the cover can be removed with the relief 
valve still mounted onto the cover.  
Prior to removing the cover, the general position should be marked in relationship to the 
housing.  Once done, remove the cover bolts and the cover. 

 

!

       

CAUTION

 

 
When removing the cover, the idler gear will generally stay on the pin.  Avoid tilting the cover 
downward as the idler may slide off, causing injury or damage.  
 

 

REMOVE THE COVER GASKET: 

 
If a new gasket is not available, reuse of the original gasket is acceptable, provided it is not 
torn or otherwise damaged. 

 

Summary of Contents for GG015

Page 1: ...Service Manual 73 Installation and Service Instructions GlobalGear Series Pumps ...

Page 2: ...oard Mechanical Seal Installation Page 23 Out Board Mechanical Seal Installation Page 23 Drive Module Rebuild Installation Page 25 Cover Idler Gear Installation Page 26 Relief Valve Installation Page 26 End Clearance Adjustment Page 27 Relief Valve Disassembly Page 29 Relief Valve Assembly Page 29 Pressure Adjustment of Relief Valve Page 29 Troubleshooting Page 30 Material Returns Page 32 Introduc...

Page 3: ...d into the pump through the suction port The liquid fills the spaces between the teeth of the idler and the rotor and is carried past the crescent partition through the pressure side of the pump When the teeth mesh on the pressure side the liquid is forced from the spaces and out through the discharge port The materials furnished for each pump are selected to suit individual applications Modular D...

Page 4: ...ty max pressure Construction size max speed USGPM LPM PSI BAR GG015 1800 15 57 200 13 8 GG030 1800 30 114 200 13 8 GG050 1500 50 189 200 13 8 GG070 1500 70 265 200 13 8 cast iron GG080 1500 80 303 200 13 8 GG090 1500 90 341 200 13 8 GG120 1200 120 454 200 13 8 GG130 1000 130 492 200 13 8 GG200 1000 200 757 200 13 8 GG210 800 210 795 200 13 8 GG015 1200 10 38 150 10 3 GG030 1200 20 75 150 10 3 GG05...

Page 5: ...rt as possible in order to avoid excessive pressure drops and must be airtight Locate the pump as close to the source of supply as conditions permit and if possible below the level of the liquid in the reservoir When necessary to locate the pump in a pit provisions should be made to safeguard against flooding When handling high viscosity liquids the speed of the pump must be reduced and the size o...

Page 6: ...emperature has reached it s operating temperature Direct drive through a traditional flexible coupling is recommended However do not expect the coupling to compensate for misalignment Contact the coupling manufacturer to determine the maximum amount of misalignment that the coupling can be subjected to Never operate the pumps without all the guards in place Pumps operating with bi directional rota...

Page 7: ...0 days Idler Bushing Idler bushings that are used with standard solid idler pins are fully lubricated by the pumped fluid and are maintenance free Idler bushings that are used with optional greasable idler pins must be re lubricated at least every 500 hours or 60 days Recommended Lubricants Recommended Temperature Range Minimum Maximum Description Manufacturer Grade Deg F Deg C Deg F Deg C Lubripl...

Page 8: ...070 GG080 GG090 GG120 GG130 GG200 GG210 RELIEF VALVE ASSEMBLY HOUSING PORTS BRACKET BUSHING ASSEMBLY BRACKET BUSHING COVER PIN ASSEMBLY IDLER BUSHING ASSEMBLY IDLER BUSHING ROTOR SHAFT ASSEMBLY MECHANICAL SEAL OR PACKING GLANDS BEARING CARRIER INNER BEARING CAP OUTER BEARING CAP BALL BEARING FOOT see note PUMP SIZE Figure 2 Note Pumps with 180 ports have a housing with a cast integral foot These d...

Page 9: ...rough the suction or discharge lines Ensure that the pump has cooled a safe temperature prior to performing any work on the pump Pump Disassembly Partial The GG Series of pumps provides the ability to rebuild the internal pumping components of the pump without removing the pump housing from the baseplate This is accomplished by removing the cover and idler gear from the front end of the pump and t...

Page 10: ...30 0 001 0 007 0 038 0 178 GG050 0 002 0 008 0 051 0 203 GG070 0 002 0 008 0 051 0 203 GG080 0 002 0 008 0 051 0 203 GG090 0 002 0 008 0 051 0 203 GG120 0 002 0 009 0 064 0 229 GG130 0 002 0 009 0 064 0 229 GG200 0 003 0 009 0 089 0 229 GG210 0 003 0 009 0 089 0 229 Table 3 Idler Bushing Clearances Note Many Tuthill pumps are provided with non standard clearances for use with high viscosity or hig...

Page 11: ... bracket Note The standard bracket for the GlobalGear pumps provides a vent to the seal chamber from suction port of the housing see Figure 4 Position the bracket so the vent hole lines up with the hole in the housing by the suction port If the viscosity of the application is greater than 7500 SSU 1650 cst the orifice plug should be removed Internal Flush Holes 1 4 NPT Plugs Suction Port Orifice F...

Page 12: ...he flow ports are unobstructed Place the valve gasket on the housing or cover Assemble the valve on the pump housing or cover with valve screws Make certain the adjusting screw of the valve points towards the suction port CAUTION The adjusting screw of the valve must point towards the suction port The end clearances can now be set Refer to instructions on page 27 Fastener Size M6 6 9 8 12 M8 14 21...

Page 13: ...ing any work Disconnect the drive so that it cannot be started while work is being performed Review the Material Safety Data Sheet MSDS applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling Vent all pressure within the pump through the suction or discharge lines Ensure that the pump has cooled a safe temperature prior to perfor...

Page 14: ... gland Remove the packing Packing Gland Stud Nut Washer Ball Bearing Assembly Bearing Lock Washer Locknut Figure 6 Pump with Packing B Pumps with single seal behind the bushing Out Board location see Figure 10 Remove the gland nuts and washers Remove the gland and gland gasket Remove the seal head from the shaft Remove the seal seat from the gland Remove the out board seal collar Remove the pin fr...

Page 15: ... in order to remove minor defects Install the locating collar see Figure 7 Using a needle nose pliers or similar tool install the locating pin by inserting it through the hole in the bracket into the hole in the shaft Position the collar so the side with the slot for the locating pin is towards the housing Slide the collar over the shaft until it engages with the locating pin Install the stationar...

Page 16: ... the shaft so the bearing may have to be tapped on Ensure that it bottoms out on the shaft shoulder The bearing must be pressed on the inner race not the outer race Pressing on the outer race could damage the bearing CAUTION Do not use excessive force when pressing the bearing onto the pump shaft as it could damage the mechanical seal Install the bearing lock washer and locknut After the locknut i...

Page 17: ...mp has cooled a safe temperature prior to performing any work on the pump REMOVE THE PUMP FROM BASE The pump can be removed from the base for service or it can be disassembled without disturbing the housing provided a spacer coupling was originally installed IF NECESSARY REMOVE SAFETY RELIEF VALVE If the pump has a safety relief valve mounted on it remove it by loosening the bolts that mount it to...

Page 18: ... support the housing on the cover side so it will not fall Remove the bolts that hold the bracket to the housing On pumps that do not have a cast integral foot remove the bolts that attach the foot to the bearing carrier The drive module assembly can then be pulled from the housing as a single unit Caution should be used as the drive modules can be heavy The use of a lifting device may be required...

Page 19: ... seat from the gland Remove the out board seal collar Remove the pin from the shaft To do this remove the plug in the NPT hole in the bracket Using a needle nose pliers or similar tool remove the locating pin from the hole in the shaft The rotor and bracket can now be separated D Pumps with cartridge seal Consult the separate seal instructions provided bt the seal manufacturer CLEAN AND INSPECT Cl...

Page 20: ... proper torque specifications Prior to reassembly ensure that all items are cleaned thoroughly and free of any metal burrs INSERT NEW IDLER BUSHING if necessary A Bronze or standard carbon bushings Insert the new bushing with the assistance of a hand arbor press The bushing should be flush to slightly below the face of the idler Ensure that the bushing does not protrude beyond the surface of the i...

Page 21: ...sistant gloves when handling hot components INSERT NEW BRACKET BUSHING if necessary A Bronze or standard carbon bushings Insert the new bushing with the assistance of a hand arbor press Always install the bushing from the chamfered end of the bracket CAUTION Special care must be taken during the insertion of carbon bushings Ensure that the bushing diameter and idler bore are parallel as any misali...

Page 22: ...e 8 Bracket Bushings 1 INSTALL PACKING OR SEAL A Pumps with packing It is always good practice to install new packing during a complete rebuild New packing sets are available from an authorized Tuthill distributor Install and seat each ring into the bracket stuffing box and stagger cut joints from one side of the shaft to the other Loosely install the gland using the gland studs nuts and washers T...

Page 23: ...rocess as any minor scratch could result in leakage once in service Insert a new o ring on the OD of the in board seal gland Lightly lubricate the o ring Insert the seal seat into the in board seal gland bore If the seal needs an anti rotation pin make sure the pin is aligned with the slot in the seal seat Install the in board seal gland into the bracket making sure the pin is aligned with the hol...

Page 24: ...ages with the locating pin INSTALL THE STATIONARY SEAT INTO THE GLAND see Figure 7 Lightly lubricate the o ring on the stationary seat and then press the seat into the gland If the gland has an anti rotation pin make sure the pin is aligned with the slot in the seal seat INSTALL THE MECHANICAL SEAL ONTO THE SHAFT Lightly polish the shaft in order to remove any minor defects Place the seal head on ...

Page 25: ...rd Note The standard bracket for the GlobalGear pumps provides a vent to the seal chamber from suction port of the housing see Figure 4 Position the bracket so the vent hole lines up with the hole in the housing by the suction port If the viscosity of the application is greater than 7500 SSU 1650 cst the orifice plug should be removed Install the bearing carrier onto the bracket Place the inner be...

Page 26: ... IDLER ASSEMBLY Place the gasket on the cover Tilt the top of the cover away from the pump until the crescent can be fitted into the rotor I D Then rotate the idler until its teeth mesh with the rotor teeth Assemble with cover bolts INSTALL RELIEF VALVE TO THE HOUSING OR COVER Prior to reinstalling the relief valve back onto the pump housing or cover ensure that the valve is clear of any foreign m...

Page 27: ...remove the feeler gages or gage blocks Note the position on the outer bearing cap where the dimension was taken 4 Loosen the two hex head bolts on the outer bearing cap 5 Slowly and evenly tighten the two setscrews on the outer bearing cap until there is a gap slightly larger than the distance measured in step 3 above 6 Determine the proper end clearance refer to Table 5 and add that dimension to ...

Page 28: ... 254 0 381mm GG210 0 008 0 010 inch 0 203 0 254mm 0 013 0 015 inch 0 254 0 381mm Table 5 End Clearance Values for standard clearances Note Many Tuthill pumps are provided with non standard clearances for use with high viscosity or high temperature fluids Consult the factory for clearances of these pumps 1 REFIT COUPLING AND GUARD If you have been able to take advantage of the modular design of thi...

Page 29: ...f components Re Assembly Of Relief Valve See Figure 12 1 Ensure all parts are clean no foreign matter is in the valve and the ports are unobstructed 2 Reassemble valve in the reverse manner as noted in Disassembly Procedure 3 Reset the adjusting screw to the original position Pressure Adjustment Of Relief Valve The safety relief valves supplied on GG Series pumps are provided with springs that can...

Page 30: ...ve normal operating pressure presented by the system to ensure the valve does not operate during normal use CAUTION If there is some other flow control device present in the system that will vary the system pressure the relief valve setting should be set above this pressure to ensure the valve does not function during normal use 10 Tighten the lock nut 11 Install the adjusting screw cap and gasket...

Page 31: ...ump g Increased clearances or wear in the pump will sometimes cause the pump to deliver an insufficient supply of liquid This may be corrected by reducing the thickness of the cover gaskets A folded gasket or a slight amount of dirt can exaggerate the problem and cause leakage Refer to Assembly Procedure section for minimum end clearances 3 Problem Pump works spasmodically a Leaky suction lines b ...

Page 32: ...rate that will prevent excessive heating on the bracket at the packing area Material Returns If it becomes necessary to return a pump to the factory a Return Goods Authorization RGA must be obtained from either your local Authorized Distributor or our Alsip plant No RGA can be issued until a completed Material Safety Data Sheet MSDS has been forwarded to our Alsip plant and return of the pump appr...

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