Tuthill GG120 Maintenance Manual Download Page 73 | Manualshive

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© Tuthill Corporation. All rights reserved. Tuthill confidential.

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Grease and oils designed to take years to break

down

•

Contaminants of moisture and particulate from

dust and dirt degrade grease and oils

•

Cleanliness is critical

•

Tips of grease guns need to be clean

Lubrication Helpful Hints

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Summary of Contents for GG120

Page 1: ... Tuthill Corporation All rights reserved Tuthill confidential Maintenance Training Module 2 GlobalGear with Cartridge Mechanical Seals ...

Page 2: ...s in Maintenance Module 2 Reassembly of Drive Module Reinstall Drive Module Adjusting End Clearance Mechanical Seal Installation Relief Valve Disassembly Relief Valve Troubleshooting Servicing High Temperature Greased Bearing Units Replacing Bushings Lubrication Notes ...

Page 3: ... Tuthill Corporation All rights reserved Tuthill confidential Reinstall the rotor into the bracket Reassembly of the Drive Module ...

Page 4: ... Tuthill Corporation All rights reserved Tuthill confidential Pick up external ball bearing Reassembly of the Drive Module ...

Page 5: ... Tuthill Corporation All rights reserved Tuthill confidential Reinstall bearing into bearing carrier Reassembly of the Drive Module ...

Page 6: ... Tuthill Corporation All rights reserved Tuthill confidential Reinstall inner bearing cap using fasteners Reassembly of the Drive Module ...

Page 7: ...hill Corporation All rights reserved Tuthill confidential Move cartridge mechanical seal into position Have flush ports in correct orientation Very loosely tighten gland nuts Reassembly of the Drive Module ...

Page 8: ... Tuthill Corporation All rights reserved Tuthill confidential Reinstall bearing carrier Reassembly of the Drive Module ...

Page 9: ... Tuthill Corporation All rights reserved Tuthill confidential Push rotor all the way in the bracket Reassembly of the Drive Module ...

Page 10: ... Tuthill Corporation All rights reserved Tuthill confidential Insert lock washer with tabs If there is a bearing spacer bearing spacer goes on first Reassembly of the Drive Module ...

Page 11: ... Tuthill Corporation All rights reserved Tuthill confidential Install locknut Reassembly of the Drive Module ...

Page 12: ...ation All rights reserved Tuthill confidential Reassembly of the Drive Module LocknutTorqueRequirements Nut Size Pump Size Newton Meters N 05 GG15 30 68 95 N 07 GG120 210 136 176 N 08 GG250 163 203 KM 12 GG550 163 203 ...

Page 13: ... Tuthill Corporation All rights reserved Tuthill confidential Bend over tab of lock washer into slot on locknut Reassembly of the Drive Module ...

Page 14: ...thill Corporation All rights reserved Tuthill confidential Check and make sure that the gasket is in the correct position for flush Center of three holes at flush opening is correct Reinstall Drive Module ...

Page 15: ...rporation All rights reserved Tuthill confidential Gasket must align to allow flow through internal flush drilling size GG250 smaller NPT plug indicates internal flush path at this location Reinstall Drive Module ...

Page 16: ... Tuthill Corporation All rights reserved Tuthill confidential Reinstall Drive Module PositionDriveModuleOverFootandNearHousing ...

Page 17: ... Tuthill Corporation All rights reserved Tuthill confidential Reinstall Drive Module PushDriveModuleintoHousing ...

Page 18: ... Tuthill Corporation All rights reserved Tuthill confidential Reinstall Drive Module FastenBoltsConnectingBrackettoHousing ...

Page 19: ... Tuthill Corporation All rights reserved Tuthill confidential Reinstall Drive Module FastenBoltsConnectingBearingCarriertoFoot ...

Page 20: ... Tuthill Corporation All rights reserved Tuthill confidential End clearance is distance between the rotor idler end and the closest surface on the cover Adjusting End Clearance ...

Page 21: ...Tuthill Corporation All rights reserved Tuthill confidential Loosen set screws on rear cover Slowly and gradually tighten hex nuts on rear cover until rotor touches the pump cover Adjusting End Clearance ...

Page 22: ... Tuthill Corporation All rights reserved Tuthill confidential When rotor is touching cover there will be a slight drag when turning the shaft Key in place Adjusting End Clearance ...

Page 23: ...thill confidential Measure the gap between the end the end cover and the bearing carrier at four places 90 apart Make small adjustments to set screws and or hex nuts so that the gap is the same at all four measured points Adjusting End Clearance ...

Page 24: ... Tuthill Corporation All rights reserved Tuthill confidential Record the gap measurement with the rotor touching the cover This is zero end clearance Adjusting End Clearance ...

Page 25: ...ved Tuthill confidential Refer to TPC 254 for Tuthill recommended end clearance Add the value from TPC 254 to the gap measurement for zero clearance This will be the target gap measurement for end clearance setting Adjusting End Clearance ...

Page 26: ...Tuthill Corporation All rights reserved Tuthill confidential Loosen hex bolts several complete turns Tighten set screws on rear cover enough to achieve the target gap measurement Adjusting End Clearance ...

Page 27: ...ake adjustments to set screws hex nuts so that the measured gap is the same 4 points 90 apart Do final even tightening of the set screws hex nuts measure again to confirm the same measurements of the gap at 4 points 90 apart Adjusting End Clearance Gap is the Same ...

Page 28: ... Tuthill Corporation All rights reserved Tuthill confidential Final tightening of hex bolts to secure the rear cover in place Adjusting End Clearance ...

Page 29: ... Tuthill Corporation All rights reserved Tuthill confidential If adjustment is being done in the shop clearances can be measured directly from the open flanges Adjusting End Clearance ...

Page 30: ... Tuthill Corporation All rights reserved Tuthill confidential After final tightening for end clearance rotate the shaft by hand to confirm that the shaft rotates freely Adjusting End Clearance ...

Page 31: ... Tuthill Corporation All rights reserved Tuthill confidential With cover removed check clearance between rotor outer diameter and housing inner diameter at 4 points 90 apart Adjusting Radial Clearance ...

Page 32: ... Tuthill Corporation All rights reserved Tuthill confidential Hex nuts can be adjusted to change radial rotor position Set screws may also need adjustment Adjusting Radial Clearance ...

Page 33: ... Tuthill Corporation All rights reserved Tuthill confidential Final Tightening of Fasteners RecommendUsingaTorqueWrench Fastener Size Newton meters M6 8 12 M8 19 28 M10 41 54 M12 75 88 ...

Page 34: ...dential For all pumps tightening of the mechanical seal is the last step for reassembling pump Gland nuts should only be barely started tightened and seal cartridge left loosely in place until the final seal tightening Final Tightening of Mechanical Seals ...

Page 35: ...rights reserved Tuthill confidential Mechanical seal has a limited travel range for self alignment and it is best to reserve the travel range for end clearance adjustments done in the field Final Tightening of Mechanical Seals ...

Page 36: ... Tuthill confidential Have flush ports in the correct position for piping Install the mechanical seal flush and square to the stuffing box Support the seal weight to center the seal cartridge on the shaft Final Tightening of Mechanical Seals ...

Page 37: ... Tuthill Corporation All rights reserved Tuthill confidential Tighten gland nuts in an even alternating pattern Final Tightening of Mechanical Seals ...

Page 38: ... Tuthill Corporation All rights reserved Tuthill confidential Tighten mechanical seal set screws in an even alternating pattern Final Tightening of Mechanical Seals ...

Page 39: ... Tuthill Corporation All rights reserved Tuthill confidential Remove fasteners securing the relief valve Removal of the Relief Valve ...

Page 40: ... Tuthill Corporation All rights reserved Tuthill confidential Relief valve and gasket removed Removal of the Relief Valve ...

Page 41: ... Tuthill Corporation All rights reserved Tuthill confidential Disassembly of the Relief Valve ...

Page 42: ... Tuthill Corporation All rights reserved Tuthill confidential Use large wrench to remove cap Disassembly of the Relief Valve ...

Page 43: ... Tuthill Corporation All rights reserved Tuthill confidential Relief valve cap removed Disassembly of the Relief Valve ...

Page 44: ... Tuthill Corporation All rights reserved Tuthill confidential Loosen jam nut using large wrench Remove bonnet using large wrench Disassembly of the Relief Valve ...

Page 45: ... Tuthill Corporation All rights reserved Tuthill confidential Bonnet removed Disassembly of the Relief Valve ...

Page 46: ... Tuthill Corporation All rights reserved Tuthill confidential Spring guide removed Disassembly of the Relief Valve ...

Page 47: ... Tuthill Corporation All rights reserved Tuthill confidential Remove spring Disassembly of the Relief Valve ...

Page 48: ...ights reserved Tuthill confidential Orange paint on spring indicates high pressure spring range 10 17 bar for full bypass No orange bands indicates standard pressure range 3 10 bar for full bypass Disassembly of the Relief Valve ...

Page 49: ... Tuthill Corporation All rights reserved Tuthill confidential Remove poppet Disassembly of the Relief Valve ...

Page 50: ... Tuthill Corporation All rights reserved Tuthill confidential Potential Problems with Relief Valves ...

Page 51: ...rporation All rights reserved Tuthill confidential Poppet sealing edge and or poppet seat not clean Result will be bypassing Corrective action is to clean the poppet and seat Potential Problems with Relief Valves ...

Page 52: ... Tuthill Corporation All rights reserved Tuthill confidential Relief valve chattering Relief valve bypassing flow Cause is relief valve set too low Potential Problems with Relief Valves ...

Page 53: ... Tuthill Corporation All rights reserved Tuthill confidential Correction is to increase the setting for full bypass pressure Higher pressure spring may be required Potential Problems with Relief Valves ...

Page 54: ...n All rights reserved Tuthill confidential Remove cap Start pump Slowly close discharge valve completely Read pressure gauge on pump discharge This is current full bypass pressure setting Setting Relief Valve in the Field ...

Page 55: ...ll Corporation All rights reserved Tuthill confidential Must know highest normal differential pressure Set relief valve to 50 higher than highest normal differential pressure Setting Relief Valve in the Field ...

Page 56: ... Tuthill Corporation All rights reserved Tuthill confidential 1 Loosen jam nut 2 Use adjusting nut to set pressure on gauge to target setting Setting Relief Valve in the Field 2 1 ...

Page 57: ... Tuthill Corporation All rights reserved Tuthill confidential 3 Once desired pressure setting is achieved tighten jam nut 4 Replace cap 5 Open discharge valve Setting Relief Valve in the Field 4 3 ...

Page 58: ...rights reserved Tuthill confidential Setting Relief Valve in the field should be accomplished in ten minutes or less Do not run the pump in full bypass for extended periods to avoid overheating Setting Relief Valve in the Field ...

Page 59: ... Tuthill Corporation All rights reserved Tuthill confidential 1 Hold relief valve inverted as shown 2 Drop in poppet feet down Reassemble Relief Valve ...

Page 60: ... Tuthill Corporation All rights reserved Tuthill confidential 3 Drop in spring 4 Drop in spring guide Setting Relief Valve in the Field 4 3 ...

Page 61: ... Tuthill Corporation All rights reserved Tuthill confidential Holding relief valve inverted Reassemble Relief Valve ...

Page 62: ... Tuthill Corporation All rights reserved Tuthill confidential Reinstall bonnet using Teflon pipe dope on threads Reinstall cap using pipe dope on threads Reassemble Relief Valve ...

Page 63: ... Tuthill Corporation All rights reserved Tuthill confidential Remove bearing cover fasteners Removing High Temp Greased Bearings ...

Page 64: ... Tuthill Corporation All rights reserved Tuthill confidential Greased bearings have a special bearing cover Greased bearings have a grease fitting Removing High Temp Greased Bearings ...

Page 65: ... Tuthill Corporation All rights reserved Tuthill confidential Remove bearing cover Remove outer bearing cap hex nuts Remove outer bearing cap Removing High Temp Greased Bearings ...

Page 66: ... Tuthill Corporation All rights reserved Tuthill confidential Remove inner bearing cap fasteners Removing High Temp Greased Bearings ...

Page 67: ... Tuthill Corporation All rights reserved Tuthill confidential Push Back Inner Bearing Cap Toward Mechanical Seal Cartridge Removing High Temp Greased Bearings ...

Page 68: ...ved Tuthill confidential Greased bearings are shrunk onto the shaft for interference fit Must be pulled off with a bearing puller Best practice is not to reuse a bearing that has been pulled off a shaft Removing High Temp Greased Bearings ...

Page 69: ... Tuthill Corporation All rights reserved Tuthill confidential Use recommended lubricant or equivalent Add grease to the grease fitting using a grease gun Greasing High Temperature Bearings ...

Page 70: ...tion All rights reserved Tuthill confidential Old grease will come out here Old grease will slip under the lip seal Add new grease until a color change is observed with the old grease Greasing High Temperature Bearings ...

Page 71: ... Tuthill confidential Can be pressed out with a hydraulic press Need to be pressed in with one forceful movement with no stops or hesitation Stopping mid way or hesitation may result in breaking the carbon bushing Helpful Hint Carbon Bushings ...

Page 72: ...ential Tungsten Carbide Bushings can be pressed out with a hydraulic press Bracket or idler needs to be heated to 425 C before installing tungsten carbide bushings Safety provisions for handling hot materials required Helpful Hint Tungsten Carbide Bushings ...

Page 73: ...uthill confidential Grease and oils designed to take years to break down Contaminants of moisture and particulate from dust and dirt degrade grease and oils Cleanliness is critical Tips of grease guns need to be clean Lubrication Helpful Hints ...

Page 74: ...hill confidential Grease fittings should be cleaned before using Work environment should be clean so as to avoid introducing particulate into grease or oil Use manufacturer recommend lubricants or cross over equivalents Lubrication Helpful Hints ...

Page 75: ...ve maintenance is to identify the need for equipment overhaul before a breakdown Planned maintenance is less expensive than responding to break downs Planned maintenance has much less impact on potential loss of production or disruption to production schedules Predictive Maintenance ...

Page 76: ...oming maintenance requirements Bearing temperature increases of 10 C from baseline is an alarm level 20 C increase over baseline is an immediate action level Vibration level increases by a factor of 2 above baseline is an alarm level vibration increase of 2 5 times baseline is an immediate action level Predictive Maintenance Howtoknowwhenmaintenanceisnecessary ...

Page 77: ...ll rights reserved Tuthill confidential Record temperatures as degrees above ambient Bearing temperature from the pump gear reducer and motor Predictive Maintenance Suggestionistorecordmonthlybearingtemp andvibrationreadings ...

Page 78: ...ration All rights reserved Tuthill confidential Learn More About Tuthill Visit Our Websites www tuthillpump com www tuthill com Like Us on Facebook www facebook com tuthillcorporation Follow Us on Twitter TuthillCorp ...

Page 79: ... Tuthill Corporation All rights reserved Tuthill confidential Excellenceatwork Excellenceinlife ...

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