5000 Gerotor Pump Service Instructions

Transcription

1 Instruction Sheet P/N B WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Introduction This instruction sheet explains procedures for rebuilding the gerotor pump on the 5000-series bulk melters. Gerotor pump service kits are available in the following configurations: The UpTime service kit contains only the replaceable seals for a 5000-series gerotor pump. Use the UpTime service kit when the pump leaks but still functions. The UpTime Plus service kit contains all pump seals and hardware items necessary for a comprehensive rebuild of a 5000-series gerotor pump. Use the UpTime Plus service kit when the pump fails to deliver material. Refer to the bulk melter manual for information not included in this instruction sheet.

2 2 Disassembly WARNING: System or material pressurized. Relieve pressure. Failure to observe may result in serious burns. WARNING: Disconnect and lock out system power before servicing equipment. External Components See Figure 1. Remove the external components from the gerotor pump using the following procedure. 1. Remove the gerotor pump from the bulk melter assembly. Refer to the Repair section of the bulk melter manual for gerotor pump removal instructions. 2. Loosen the set screw (6) on the shaft coupling block (5). 3. Remove the shaft coupling block, key (15), and bearing washer (7) from the pump shaft (14). 4. Remove the socket head screws (3) securing the manifold (8) to the pump body (13). Remove the manifold. 5. Remove the pipe plugs (1, 11), hose connectors (4), and manual valve (2) from the manifold. 6. Remove the pressure relief valve (9) from the pump body. 7. Remove and discard the pressure relief valve O-rings (10, 12).

3 Figure 1 External Gerotor Pump Parts 1. Pipe plug 2. Manual valve 3. Socket head screws 4. Hose connector 5. Shaft coupling block 6. Set screw 7. Bearing washer 8. Manifold 9. Pressure relief valve 10. O-ring 11. Pipe plug 12. O-ring 13. Pump body 14. Pump shaft 15. Key

4 4 Internal Components See Figure 2. Remove the internal parts from the gerotor pump using the following procedure. NOTE: 5000 gerotor pumps are equipped with either a wear plate (16) or a retaining ring (10) against the lower pump plate (17). If your pump is equipped with a wear plate, disregard steps pertaining to the retaining ring. If your pump is equipped with a retaining ring, disregard steps pertaining to the wear plate. 1. Remove and discard the O-rings (1, 3) from the pump body (2). 2. Remove the socket head screws (19) securing the lower pump plate (17) to the pump assembly. Remove the lower pump plate and wear plate (16) (if used). 3. Remove the socket head screws (15) securing the gerotor retainer (14) to the pump assembly. Remove the gerotor retainer. 4. Remove the outer gerotor gear (13) from the gerotor retainer. 5. Remove the pump shaft (8), inner gerotor gear, and Woodruff key (9) from the pump body. 6. Remove the retaining ring (10) (if used) from the lower pump plate (17). 7. Remove the shaft seal (11) and back up ring (12) from the lower pump plate. 8. Remove the closed-needle bearing (18) from the lower pump plate. 9. Remove the upper pump plate (7) from the pump body. 10. Remove the shaft seals (4) and back up rings (5) from the pump body. 11. Remove the open-needle bearings (6) from the pump body.

5 Figure 2 Internal Gerotor Pump Parts 1. O-ring 2. Pump body 3. O-ring 4. Shaft seals 5. Back up rings 6. Open-needle bearings 7. Upper pump plate 8. Pump shaft 9. Woodruff key 10. Retaining ring Shaft seal 12. Back up ring 13. Outer gerotor gear 14. Gerotor retainer 15. Socket head screws 16. Wear plate 17. Lower pump plate 18. Closed-needle bearing 19. Socket head screws

6 6 Cleaning the Components CAUTION: Do not heat Type-R solvent above 245 C (475 F). Do not use an open flame or an unregulated heating device. Failure to observe this caution may cause a fire hazard. CAUTION: Use extreme caution when selecting a solvent other than Type-R solvent. Solvents may present a toxic or fire hazard. Follow these guidelines to clean the 5000 gerotor pump components before assembling the pump. Type-R solvent may not be compatible with the material being removed. Test for compatibility with a small sample of material and Type-R solvent. If cleaning a moisture-curing urethane from pump components, use a cleaner recommended by the adhesive manufacturer. Heat the pump and manifold components in a container of Type-R solvent to the melting temperature of the material being removed. Use a fiber brush or similar nonmetal device to remove adhesive, char, or other debris from each of the components. Assembly Use the following procedures to assemble the gerotor pump. Internal Components See Figure 2. Use the following procedure to assemble the internal components of the gerotor pump. 1. Use your fingers to coat the interior and exterior of both open-needle bearings (6) with high-temperature grease. 2. Press one open-needle bearing into the top of the manifold end of the pump body (2) until it is 12 mm (0.471 in.) below the top surface. Press only against the flat side of the bearing race where the bearing designation is marked. 3. Press the second open-needle bearing into the bottom of the gerotor end of the pump body until it is 9.2 mm (0.362 in.) inside of the pump body. Press only against the flat side of the bearing race where the bearing designation is marked.

7 7 CAUTION: Each shaft seal (4) must be installed with its back up ring (5) facing the open needle bearing (6). The expansion spring inside of the seal must be visible when the seals are installed. 4. Apply a light coating of high-temperature grease to the shaft seals (4). Install one shaft seal and back up ring (5) into the top of the pump body. Install the other shaft seal and back up ring in the bottom of the pump body. The back up rings should seat against the bearings and the expansion spring inside the seal should be visible when the seals are installed. 5. Coat the interior and exterior of the closed-needle bearing (18) with high-temperature grease. Press the closed-needle bearing into the lower pump plate (17) until the open end of the bearing is one of the following specified distances from the inner face of the pump plate: Pumps with a retaining ring: 10.2 mm (0.40 in.) Pumps with a wear plate: 7.6 mm (0.301 in.) CAUTION: The shaft seal (11) must be installed with its back up ring (12) facing the closed needle bearing (18). The expansion spring inside of the seal must be visible when the seal is installed. 6. Apply a light coating of high-temperature grease to the new shaft seal (11). Install the shaft seal and back up ring (12) in the lower pump plate until it seats against the bearing. The expansion spring should be visible when the shaft seal is installed. 7. If your pump uses a retaining ring (10), install it in its groove above the shaft seal in the lower pump plate. CAUTION: Ensure that the crescent-shaped cutout in the upper pump plate is positioned as shown in Figure 2. Damage to the pump may result if the upper pump plate is positioned incorrectly. 8. Position the upper pump plate (7) against the pump body. 9. Install the Woodruff key (9) into its key way at the lower end of the pump shaft.

8 8 Internal Components (contd) 10. Apply a light coating of high-temperature grease to the bearing surfaces of the pump shaft (8). Install the pump shaft into the bottom of the pump body. 11. Position the gerotor retainer (14) against the upper pump plate. Coat the socket head screws (15) with PTFE paste and hand-tighten them into the pump body/plate/retainer assembly. 12. Apply a light coating of high-temperature grease to the inner surface of the gerotor retainer and outer gerotor gear (13). Place the outer gerotor gear inside of the gerotor retainer. 13. Align the Woodruff key with the square-shaped key way in the inner gerotor gear. 14. Install the inner gear onto the pump shaft, turning the outer gear to mesh flush with the inner gear. NOTE: It might be necessary to shift the gerotor retainer slightly to allow the inner gear to enter the outer gear. 15. Position the gerotor retainer to allow free rotation of the inner and outer gerotor gears. Torque the socket head screws (15) to N m (12-15 ft-lb). CAUTION: Ensure that the crescent-shaped cutout in the lower pump plate and wear plate (if used) is positioned as shown in Figure 2. Damage to the pump may result if either the lower pump plate or wear plate are positioned incorrectly. 16. If your pump is equipped with a wear plate (16) set it on the lower pump plate (17), aligning it as shown. 17. Apply a light coating of high-temperature grease to the bottom of the pump shaft. Coat the socket head screws (19) with PTFE paste. Secure the lower pump plate to the gerotor retainer with the socket head screws. Alternately torque the screws to N m (12-15 ft-lb). 18. Install the pump body O-ring (3) into the groove on the pump body. 19. Install the O-ring (1) into the pump body.

9 9 External Components See Figure 1. Use the following procedure to assemble the external components of the gerotor pump. 1. Apply a small amount of high-temperature grease to the O-ring grooves in the pressure relief valve (9). Stretch the new O-rings (10, 12) only enough to move them into the grooves. Apply a small amount of high-temperature grease to the O-rings. 2. Thread the pressure relief valve into the pump body (13). Damage to the pump body threads could result if the pressure relief valve is overtightened. 3. Apply PTFE paste to the threads of the manual valve (2). Thread the manual valve into the manifold (8). Damage to the threads could result if the manual valve is overtightened. 4. Coat the threads on the hose connector (4) and pipe plugs (1, 11) with PTFE paste. Thread the hose connector and pipe plugs into the manifold. Damage to the threads could result if the manual valve is overtightened. 5. Secure the manifold to the pump body with the socket head screws (3). Torque the screws to N m (12-15 ft-lb). 6. Install the bearing washer (7), key (15), and shaft coupling block (5) onto the pump shaft. 7. Install the shaft coupling block onto the pump shaft (14). Allow mm ( in.) of end play between the manifold and shaft coupling block. Tighten the set screw (6) and recheck end play. 8. Install the gerotor pump to the bulk melter assembly. Refer to the Repair section of the bulk melter manual for gerotor pump removal instructions.

10 10 Parts See Figure 3. Use the following list to order components for the UpTime and UpTime Plus service kits for the 5000 gerotor pumps. UpTime Service Kit - 506, 5506, 5530, 5540 bulk melters Item Part Description Quantity Service kit, UpTime, 5000 gerotor O-ring, Viton, ID x wide O-ring, Viton, 5 / 8 tube O-ring, Viton, ID x wide O-ring, Viton, x x Seal, shaft, ID x Seal, shaft, ID x NS Grease, fluorinated, 2 oz tube 1 NS: Not Shown UpTime Plus Service Kit - 506, 5506, 5530, 5540 bulk melters Item Part Description Quantity Service kit, UpTime Plus, 5000 gerotor Block, coupling, shaft Washer, bearing, x x in O-ring, Viton, ID x wide O-ring, Viton, 5 / 8 tube O-ring, Viton, ID x wide O-ring, Viton, x x Seal, shaft, ID x Bearing, needle, open, in. ID Plate, pump, upper Gerotor set, 6 tooth, in. thick Key, 1 / 8 x 0.8 in Shaft, pump, 750 gerotor Key, Woodruff, #3, hardened Retaining ring, internal, 84, spiral 1 Continued on next page

11 11 Item Part Description Quantity Seal, shaft, ID x Plate, pump, lower Bearing, needle, closed, in. ID 1 NS Grease, fluorinated, 2 oz tube 1 NS: Not Shown Figure 3 Service Kit Parts

12 12 UpTime Service Kit bulk melter Item Part Description Quantity Service kit, UpTime, 5000 gerotor O-ring, Viton, ID x wide O-ring, Viton, 5 / 8 tube O-ring, Viton, ID x wide O-ring, Viton, x x Seal, shaft, 0.63 ID x D Seal, shaft, 0.63 ID x D 1 NS Grease, fluorinated, 2 oz tube 1 NS: Not Shown UpTime Plus Service Kit bulk melter Item Part Description Quantity Service kit, UpTime Plus, 5000 gerotor Block, coupling, shaft Washer, bearing, x x in O-ring, Viton, ID x wide O-ring, Viton, 5 / 8 tube O-ring, Viton, ID x wide O-ring, Viton, x x Seal, shaft, 0.63 ID x D Bearing, needle, open, in. ID Plate, pump, upper Gerotor set, 6 tooth, in. thick Key, 1 / 8 x 0.8 in Shaft, pump, 750 gerotor Key, Woodruff, #3, hardened Retaining ring, internal, 84, spiral Seal, shaft, 0.63 ID x D Plate, pump, lower Bearing, needle, closed, in. ID 1 NS Grease, fluorinated, 2 oz tube 1 NS: Not Shown Issued 08/03 Original copyright date Nordson and the Nordson logo are registered trademarks of Nordson Corporation. Viton is a registered trademark of E.I. DuPont de Nemours & Co.