Hypro Series 93HPS Hydraulically Driven Wetseal Multistage Pumps Repair Manual KEEP FOR FUTURE REFERENCE Form L-1578R Rev. A SERIES 93HPS Hydraulically Driven Stainless Steel Multistage Centrifugal Pumps with Wetseal Technology Pentair 375 5th Ave., New Brighton, MN 55112 Phone: (651)766-6300 -OR- 800-424-9776 Fax: 800-323-6496 www.hypro.pentair.com EU Authorized Representative: EC REP QNET BV Hommerterweg 286 6436 AM Amstenrade, The Netherlands KvK Zuid-Limburg 14091511 1
To Take the Pump Apart 1. Prior to full disassembly, the barrier fluid must be drained from the chamber. Using a 8mm [5/16 ] wrench, remove the top plug in the mounting flange. Note: There may be a slight amount of vacuum or pressure in the chamber, so loosen slowly. Drain the fluid from the mounting flange. The fluid should be green in color. If it appears fouled or severely diluted, a seal repair kit should be installed. Repair Instructions 5. Remove the shell. Then remove the stack. 6. Next you will have to remove the small shaft adaptor. Place a 9/16 wrench through the inlet of the pump to prevent the shaft from rotating. Using an 11mm hex bit, remove the shaft adaptor. 2. Using a 1.25 hex bit, remove the discharge casting from the shell. You may need to use a strap wrench on the shell to prevent it from turning with the discharge. Place the strap wrench closest to the inlet casting to avoid denting the shell. 7. Using a 17mm socket or wrench, remove the (4) hex head bolts holding the pump inlet casing to the mounting flange. The pump casing may need to be pried off, and if so, be careful not to mar the surface of the volute or the mounting flange. 3. Before removing the shell, clean the surface with a degreaser. 4. To remove the shell, use a strap wrench. Place the strap wrench nearest to the inlet flange to prevent denting the shell. Pump Seal Removal 1. To remove the seal without contacting the shaft, use two screwdrivers positioned opposite each other, and gently pry the front rotary portion of the seal from the shaft. Take care to avoid marring the surface of the mounting flange or shaft. Remove the seal spring. The rear portion of the shaft seal will come off when the motor is removed. 2 L-1578R (Rev. A)
2. Using a 13mm [1/2 ] box end wrench, remove the 4 hex head bolts holding the motor to the mounting flange. The rear portion of the seal is still holding the motor to the mounting flange at this point. Position the mounting flange assembly with motor as shown in the photo, and with the shaft contacting the work surface, gently and slowly push straight down on the mounting flange to push the rear mechanical seal off of the motor shaft. Be careful to avoid chipping the stationary seal with the shaft since the rotating seal comes loose. 3. A socket of appropriate diameter may be used to remove the stationary portion of the mechanical seals from both Seal Replacement/Pump Housing Reassembly TIf the hydraulic motor requires repair, proceed to the Disassembly and Repair of the Hydraulic Motor. 1. Inspect the hydraulic motor shaft for scratches or marks. Any light scratches can be polished with a 300-600 grit emery cloth. Be sure to polish radially on the shaft and not along the length of the shaft, and clean the shaft with alcohol after polishing. the seal plate and the mounting flange. If an appropriate sized socket is not available, a screwdriver and mallet may be used to gently tap the seal out of the bore. The seal may be damaged by removal. A new seal 2. Support the Mounting Flange, face down, about 2 [51mm] above the working surface as shown. Install the motor onto the mounting flange, taking care to not scratch the motor shaft. Using a 13mm [1/2 ] socket, tighten the 4 bolts to 17 ft-lbs of torque. should be used when the pump is reassembled. In the case of a severe pump leak, inspect the hydraulic motor bearing for possible contamination. Clean up of Pump Housing 1. Using a circular bottle-type wire brush with air or hand drill, clean the outlet port, inlet port, and the o-ring sealing areas of the pump housing and seal flange. Using the port brush, clean the seal cavity in the mounting flange. 2. After wire brush cleaning, it is recommended that the pump housing and seal flange be further cleaned in a solvent tank to remove rust and corrosion particles. 3. Lubricate the outside diameter of the stationary seal ring, as well as the seal cavity in the mounting flange with soapy water. Do not use oil as a lubricant. 4. Make sure the seal installation tool is clean and free of debris. Install one stationary seal ring with black shiny face up into the bore of the mounting flange. Push the seal all the way into the pocket with the flat side of the installation tool facing down. 3 L-1578R (Rev. A)
5. Clean the seal face with a lint free cloth. An alcohol wipe is acceptable. 10. Position the seal onto the shaft with the shiny side of the seal facing down. Position the installation tool with the flat side up and the hollow side against the back of the seal. Slowly push the rotating seal down all the way against the stationary ring. Make sure it is pushed all the way down. 6. Lubricate the outside diameter of the other stationary seal ring, and the seal bore of the seal plate with soapy water. Do not use oil as a lubricant. 11. Install the large o-ring into the groove on the mounting flange. Make sure the o-ring is fully seated in the groove by pressing it down firmly with your fingers around the entire perimeter of both the inside and outside boundary. 7. Install the other stationary seal ring into the bore of the seal plate with black shiny face up. Push the seal all the way into the pocket using the flat side of the installation tool. 12. Install the seal spring onto the remaining rotating seal as shown. Lubricate the inside diameter of the remaining rotating seal with soapy water. Install the rotating seal and spring onto the shaft as shown. 8. Clean the stationary and rotary portion of the seals with an alcohol wipe. There must be no debris, lubricant, or fingerprints on the seal faces. 9. Using fingers or a clean q-tip, lightly lubricate the shaft, and the inside diameter of the rotating seal with soapy water. Do not use oil as a lubricant, and do not get any lubricant on the seal faces. 4 L-1578R (Rev. A)
13. Carefully install the inlet flange casting over the shaft and onto the mounting flange. The seal spring will tend to hold the inlet casting up off the mounting flange. Small clamps may be used to hold the plate in position while installing the 4 mounting bolts. Disassembly and Repair of the Hydraulic Motor The work area and motor should be as clean as possible to prevent contamination of parts. 1. After removing the Mounting Flange from the motor body, place hydraulic motor in vise. 2. Remove Hydraulic Manifold, if equipped using a 1/4 Allen wrench. 3. Remove Case Drain line, if equipped. 4. Using a 6mm Allen wrench, remove the Socket head Cap Screws from the Motor End Plate. 14. Using a 13mm socket or wrench, torque the 4 screws evenly to 22 ft-lbs in a criss-cross pattern. Be sure to fully re-torque each screw 2-3 times. This compresses the o-ring. 15. Fill the chamber with Hypro wet seal fluid # 2160-0134. The typical amount of fluid is 370mL (12.5 fl oz). This is a good time to check to make sure no fluid has leaked out of either side of the pump. Fluid will not completely fill the chamber. 5. If Motor End plate will not lift off easily, use a small screwdriver to carefully pry apart the boss portion of the End Plate and Gerotor Housing until free. If Gerotor Housing will not lift off easily, carefully pry apart the boss area between the Gerotor Housing and the Motor Body. (It may be necessary to alternate sides when prying apart Motor sections.) It is critical to use only Hypro wet seal fluid #2160-0134 for replacement. 16. Clean the pipe plug threads and install Teflon tape onto the pipe plug. Firmly tighten the plug using an 8mm [5/16 ] wrench. 6. Remove both parts of the Gerotor. It is critical that an air tight seal is achieved with the pipe plug, or the ForceField TM technology will not function properly, and the life of the pump will be reduced. 5 L-1578R (Rev. A)
7. Remove the Roll Pin from the shaft. 8. Remove the o-ring from the Motor End Plate and Body with a flat instrument such as a knife blade. If bearing is binding against the retaining ring so that it cannot easily be removed, place the motor body (threaded portion of the shaft up) on arbor press. Using a piece of un-threaded metal pipe (1 dia. x 4 high [25mm x 102mm high]), slide over the shaft and gently press down with the arbor press just enough to relieve the pressure on the retaining ring. Then remove the retaining ring. 3. Place body in position on arbor press. Threaded portion of the shaft should be inside the fixture. Press out shaft assembly with arbor press. Make sure the opening in the base of the arbor press is large enough to allow the ball bearing through. 9. Inspect Motor End Plate, Body and Gerotor Housing for wear and/or gouging. If gouging has occurred in both the Motor End Plate and Body, the motor is not repairable. If gouging has occurred in the Motor End Plate, Body, or Gerotor housing, the part that is worn must be replaced. To Remove the Shaft Assembly from the Motor Body 1. Using a 2.5mm allen wrench, loosen the 2 set screws on the Tone Wheel. Remove the Tone Wheel from the Motor Shaft. Hydraulic Motor Shaft Disassembly and Repair 1. Remove Retaining Ring from Shaft with a small snap ring pliers. Special attention should be exercised when working with retaining rings. Always wear safety goggles when working with spring or tension loaded fasteners or devices. 2. Using the large retaining ring pliers, remove the Retaining Ring next to the Ball Bearing in the Motor Body. 2. To remove the Bearing from the shaft, place the shaft (threaded end up) in the arbor press fixture, and the thrust bearing race resting on the base of the arbor press. Press the shaft through the ball bearing until the bearing comes off. 6 L-1578R (Rev. A)
3. Remove the Oil Seal and Thrust Bearing Assembly from Shaft (includes the Thrust Bearing and two Thrust Bearing Races). 5. Over the threaded end of the shaft, install the Thrust Bearing Race, Thrust Bearing, and Second Thrust Bearing Race against the Retaining Ring. Do not slide the Oil Seal over the Snap Ring Groove or it will be destroyed. 4. Inspect the sealing area of the shaft for wear. Inspect other Shaft Assembly Components for wear and replace if necessary. 5. While motor is completely disassembled, clean all parts in a solvent bath. To Install New Shaft Seal 1. The sealing lips on a new seal must be expanded to fit on the shaft. Press seal onto large end of shaft with seal lip facing out. Do not push seal past keyway on shaft. 6. With the seal lip facing the large end of the shaft, slide the seal over the threaded end of the shaft and gently push onto the raised area of the shaft, all the way down to the thrust bearing assembly Should the main needle bearings in the hydraulic motor need replacement, a new body and/or end plate with the main bearing already installed must be used. If this occurs, check other internal parts of the motor for damage and wear. 2. Once seal lip has been expanded, remove the seal from the shaft. 3. Over the large end of the shaft, install the Retaining Ring into the groove. 4. Place the shaft in a vertical position with the threaded end facing up. The Motor End Plate serves as a good holding fixture. To Install Shaft Bearing and Shaft Assembly in Motor Body Make sure the surface edge of the arbor press fixture is smooth and clean. 1. Place the hydraulic motor body in the arbor press fixture with the large bore facing upward. Take the shaft sub-assembly from the previous step, lubricate the outside diameter of the seal with light oil, and place it loosely into the Hydraulic Motor Body with the threaded end of the shaft facing upward. 7 L-1578R (Rev. A)
2. Install the spacer over the shaft and into the bearing bore. Using a 1.5 dia. 4.0 long [38 mm x 102 mm long] pipe, press on the spacer until the assembly is all the way down. 6. Thread the tone wheel set screws into the tone wheel. Install the tone wheel over the threaded end of the shaft, all the way up against the inner race of the ball bearing. 3. Install the ball bearing onto the shaft, and make sure it is squarely in position. Using the same pipe from the previous step, press on the outer ring of the ball bearing until it is all the way down into the bore. 7. Tighten the two set screws to 48 in-lbs [5.4 N-m] of torque. 4. Install the Internal Retaining Ring into the Groove on the Motor Body with a snap ring pliers. Make sure the Retaining Ring is fully seated in the Groove. Reassembly of Remaining Hydraulic Motor Parts 1. Install the O-ring in the body. 5. Flip the Motor Body Subassembly over in the arbor press, so that the unthreaded side of the shaft is pointing upward. Gently use the arbor press to push the shaft forward so that the stack of components on the shaft is pressed up against the front Retaining Ring. 2. Install the Roll Pin onto the Shaft. 3. Align the slot in the Inner Gerotor bore with the Roll Pin, and then install the Inner Gerotor onto the Shaft. Hydraulic pressure in the motor will push the shaft forward during operation. Failure to perform step 5 could result in undesired shaft movement that could cause the seals to leak. 8 L-1578R (Rev. A)
The roll pin can slide up behind the inner gear of the Gerotor when the gear is installed. Make sure the Roll Pin is visible in the slot after the gear is in place. 4. Install the outer portion of the Gerotor, making sure the Gerotor is centered within the O-ring groove on the Body. 5. Install the O-ring onto the End Plate. 9. Install the four flat washers and four Socket Head Cap Screws into the holes on the Motor End Plate. Using a 6 mm Allen wrench, tighten Cap Screws alternately and evenly in a crisscross pattern to approximately 17 foot pounds [23 N-m] of torque. 10. If equipped, replace o-rings on Hydraulic Manifold. 6. Install the Gerotor Housing onto the End Plate, making sure the pins in the Gerotor Housing line up with their respective holes in the End Plate. 11. If equipped, install Hydraulic Manifold back on the motor. 7. Lightly lubricate the area between the Inner and Outer Gerotor and Gerotor Housing with hydraulic oil or mineral oil. Also lubricate the flat face of the end plate. 13. Remove Hydraulic Motor from the vise. Turn Shaft by hand to check for binding. Motor must turn freely by hand. 8. Place End Plate with Gerotor Housing over the Gerotor, and align the pins from the Gerotor housing to the corresponding pins in the Motor Body. When all the parts are properly aligned, push the motor sections together until they are flush. 14. The motor can now be reinstalled onto the Mounting Flange as described in the Seal Replacement / Pump Housing Reassembly section. Hypro (01/18) Printed in USA L-1578R (Rev. A) 375 Fifth Avenue NW New Brighton, MN 55112 USA Phone: (651) 766-6300 800-424-9776 Fax: 800-323-6496 www.hypropumps.com