PENTAIR Myers D25-8 Industrial Pumps Instruction Manual

PENTAIR Myers D25-8 Industrial Pumps

GENERAL INSTRUCTIONS

Reciprocating pumps of both the plunger and cup type are positive displacement in principle. Due to positive displacement characteristics, problems may arise through improper installation or application. When new or unusual installations are planned, or the material to be pumped is a liquid other than cold water, the customer should consult the “Myers Reciprocating Pump Manual” or factory for additional information.

CAUTION : Positive Displacement Pumps must have a proper size and operable type of pressure regulating valve or pressure relief valve piped into the discharge line. This is mandatory to prevent damage to pump and piping or possible injury to personnel. Do not install any valves or shutoff devices in the bypass line from pressure regulator to tank or supply.

CAUTION : All pumps should be installed level. For mobile applications the maximum angle of intermittent operation should be no more than 5 degrees in any one direction.

CALIFORNIA PROPOSITION WARNING: This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

INSTALLATION

• If possible, install suction piping one pipe size larger than suction tapping in pump.
• Reduce piping size at pump with a reducer coupling as shown on installation drawings.
• A suction surge arrester, also shown, will assure smoother operation.
• Keep suction piping as short and simple as possible with a minimum of lift when operating under suction lift conditions. Avoid any high points in suction line.
• Use suction strainer and screen of adequate size to avoid restriction of pump suction. Strainer mesh should be sufficiently small to prevent passage of trash which may lodge under pump valves.
• Keep screen clean with a regular maintenance schedule When pumping liquids that are heated, reduce pump speed to avoid suction problems.
• Consult “Myers Reciprocating Pump Manual” or factory for temperature and speed limitations.
• Be sure that discharge line is properly protected by means of a pressure regulating valve and a discharge surge arrester of proper size, capacity, and pressure rating.
• The discharge line should be of comparable size to discharge tapping in pump. Diagram illustrates pr oper location of discharge surge arrester in relation to pressure regulating valve.

CORRECT LOCATION OF DISCHARGE SURGE ARRESTER WHEN USING PRESSURE REGULATING VALVE.

• Demand should not exceed 90% of pump capacity for satisfactory regulating valve operation.
• Discharge in excess of this capacity may cause unstable pressure regulator operation.
• It is also preferred to discharge in excess of 50% of pump capacity to reduce rate of erosion or wear on regulating valve and seat.
• When lower system demands (than rated pump capacity) are required in an installation, the pump speed should be reduced by changing drive ratios.
• This will reflect savings in power consumption, reduce regulating valve wear, and extend pump life.
• Where line shock or water hammer is encountered a second surge arrester should be installed in the discharge line.
• Under some conditions, it may also be desirable to isolate the pump from piping with a suitable high-pressure hose.
• This will eliminate transmission of line vibration to the pump and minimize possible failure of piping, pipe threads, and/or pump casting.
• Never pipe the bypass from a pressure-regulating valve back into pump suction.
• When discharge line is shut off, the complete bypass is circulated back into the pump suction with a resulting rapid temperature rise which will destroy packing and gaskets.
• AVOID FREEZING by draining all water from pump. Install cylinder drain valves. Remove plugs #50.
• Make sure that drive is adequate for horsepower required and that drive is properly aligned and tensioned.
• With belt drives, pulley on both motor and pump should be located as close as possible to bearing to reduce bearing and shaft bending loads.
• See unit “Operator’s Manual” for belt tension speci- fications factory installations. Make sure that all belts, nuts, set screws, and keys are properly tightened.

DIRECT DRIVE Engine-Driven Pumps

The following instructions are for applications of Dodge Para-Flex Couplings. For other cOuplings, use manufacturer’s recommendations. it is desirable to align the coupling as accurately as possible to minimize flexing of the flexible element caused by the shaft misalignment which usually develops in usage because of shifting of the driving and driven units. After any repositioning, recheck both parallel and angular alignments by mounting indicators near the O.D. of the flange as shown in Fig. 1 and rotating the shaft through 360. For a good installation neither indicator reading should exceed value in column D below. Fiange shouid be positioned on shaft to obtain dimen- sion “C” measured from adapter to rear of clamp ring. Adapter bolts should be torqued to value in column B, clamp ring bolits to value in column A

STARTING PUMP

A. Before starting:

• Read all instructions carefuly.
• Fill pump crankcase with recommended oil to level mark on oil saber. Oil recommendations are covered in lubrication section of pump instructions.
• Replace all drain plugs in pump and piping
• Inspect tank to be sure that no foreign material is in tank or suction line.
• Fill tank at least half full or connect suction to water supply. Open valve (if present) in suction line. If pumping from a pit, make sure that suction line is completely submerged.
• Make sure all valves are open in discharge line.
• Completely back off pressure adjusting screw on pressure regulating valve.

B. Start i ng the unit:

• After starting, close discharge valve slowly while watching pressure gauge to make sure relief valve or unloader is operating properly.
• Adjust relief valve or unloader to desired pressure. See regulator instructions.
• Cycle discharge on and off to be sure that pressure adjustment and regulator operation is satisfactory.

SUGGESTED MAINTENANCE SCHEDULE

LUBRICATION
Fill gear case with Mobilgear 630 or equal additive to capacity listed in chart. Maintain oil level at mark on oil dipstick. NOTE: After first 30 hours of operation drain oil from gear case (preferably drain at operating temperature), replace plug and fill gear case with kerosene to normal oil level. Operate at full speed at zero pressure for two minutes then drain, replace plug, refill crankcase with new oil as above. Change oil every 300 hours thereafter. Check oil level daily and add oil as needed

ADDITIVES FOR CRANKCASE OIL
Use of Molybdenum Disulfide (MoS2) is highly recommended by Myers as an additive to the gear case oil in back geared pumps and speed reducers manufactured by Myers. The additive is compatible with all known oils. It appears to be so effective in reducing wear and friction that power train life may be doubled between overhauls. The chart below gives volume of MoS2 concentrate for Myers Industrial and Spray Pumps.

SERVICE CAUTION: Disconnect electrical leads to motor or remove spark plug leads on engine. Following work on any internal pump parts, it is important to tighten all clamps, caps and assemblies to specific torque ratings, refer to Recommended Torque chart.

REPAIR TOOLS

• 189998  Valve Seat Installation Kit
• 1753981  Cylinder Puller Kit
• 7297A3  Valve Seat Puller Kit
• 21099A  Wrench for piston cups
• 17544A10  Puller for cup assembly
• Valve Seat  Allen wrench

V-RING PACKING Move plunger to front end of cylinder (top deal center). Remove valve assembly if required to provide clearance for pulling plunger. Remove cap screw with an Allen wrench. (Allen wrench, Part No. 857 4A 11, ¾” across flats). With plunger at extended position, back off piston rod and insert tool  until large diameter catches behind stud. Force plunger assembly from liner by rotating crankshaft slowly.

V-RING PLUNGER ASSEMBLY

INSTALLING PLUNGERS

V-Rings should be lubricated with Molykote for ease in assembly. Do not use a graphite type grease. When installing each V-Ring plunger assembly, rotate crankshaft until piston rod is at most extended position. Place copper gasket 5030A128 in position in stud, using a small amount of Permatex to hold in place. Insert plunger assembly into liner, and drive slowly in place. Cap screw should then be inserted and torqued to 25 ft.-lb. using a 3/e” across flats hexagonal socket attachment

REMOVING PLUNGERS
Bell Shaped Cups Have plunger at front end of cylinder (top dead center). Remove valve assembly if required to provide clearance for pulling plunger. Remove socket head cap screw with an Allen wrench 12mm across flats. Thread plunger removal tool onto plunger stud and pull plunger out cf cylinder liner

REPLACING PLUNGER CUPS”
Remove nut from plunger stud with a ¼” thick flat iron inserted across slots. Remove worn cup, apply nonhardening sealing compound  and replace with new cup. Thread nut back on plunger stud and tighten nut with flat iron wrench to a snug compression loading. CAUTION: Do not overtighten nut on plunger cup. Overtightening of cup will cause excessive squeeze at cup heel resulting in rapid cup wear during break-in period. Most premature cup failures are directly traceable to excessive squeeze on plunger cup during installation. Before installation of plunger in cylinder, the ring gasket seal between plunger and rod should be inspected and replaced if condition is questionable. Also inspect cylinders for linear grooving by running your thumbnail circumferentially around bore of cylinder. If any grooving is detected also replace cylinders. New cups will rapidly cut or wear out in grooved cylinders.

INSTALLING PLUNGERS

Thread plunger removal tool onto plunger stud flush with plunger nut. Lubricate plunger cup with Molykote or Lubriplate and check to be sure that ring gasket is installed in plunger stud. Retract plunger rod by rotating pump crankshaft. Install plunger by driving plunger assembly back into cylinder with a plastic hammer or wood mallet.

REMOVING CYLINDER LINERS

• First remove plungers as outlined previously.
• Rotate crankshaft until piston rod is in rear position.
• Insert puller (3) through inside of cylinder and pilot over piston rod.
• Insert disc (4) into slots on puller (3).
• Slip plate (2) over threads on puller (3) as shown.
• Screw nut (1) on thread on puller (3) and snug up.
• Tighten nut (1) until liner breaks loose.
• Loosen nut (1) and slip disc ( 4) out of slots.
• Remove puller (3) and repeat to remove remainder of cylinder liners.

INSTALLATION

Reasonable care and judgment should be used when installing the new tapered cylinder shell. Clean out any accumulation of loose rust or corrosion in tapered cylinder slots. Insert shells in position by hand and drive into position firmly (but not excessively) with a wood block and mallet. Never use a hand or hydraulic arbor press to install cylinder shells. If extreme pressures are used during installation, parts will be very difficult to remove for later replacement and liners may be distorted.

REMOVING SEATS: Ball Valves First remove cylinder and valve caps which provide access to both suction and discharge valves. Remove the stainless steel ball valves. Use tool kit 7297 A3 for removing valve seats. When removing upper valve seat, pass head of puller through hole in valve seat before sliding wedge is inserted alongside puller bolt. Draw down on nut at top of bolt. When removing lower seats drop puller bolt through opening for upper seat and remove in same manner as described above, using sliding wedge on pumps where lower seats are same size as upper seats. Use hooked tool M1688A as a wedge where lower seats are smaller. See Fig. 10A

REPLACEMENT

• Lubricate tapered valve seat bore in fluid end with Molykote and wipe out excess with a rag. Place new lower seat in tapered hole. With a hardwood round dowel, drive lower seat firmly into place with a hammer. Repeat for upper seat being sure to also lubricate the tapered bore in housing with Molykote.
• Inspect “O” rings on valve and cylinder caps. Replace if “O” rings show signs of wear, or “nibbling.” Lubricate “O” rings and replace cap, bar and nuts. Torque cap covers nuts to specification shown in torque chart.

REPLACING PLUNGER ROD SEALS

REPLACING CROSSHEAD ROD OIL SEALS

The rod seal assembly contains two seals, two oil seals with lips facing power end. The oil seal can be replaced without taking the fluid end off by removing the cylinder and piston to allow access for oil seal housing. Unscrew two Allen screws and place into the other two tapped holes. Gradually screw them in to push oil seal housing off the retainer. After assembling new seals in oil seal housing an assembly thimble should be used on end of crosshead rod for sliding oil seal housing back into retainer. Check gasket, replace if damaged. Figure 13 shows a recommended thimble for installation of oil seals. The thimble should be machined from high carbon steel and polished on the outside to reduce possiblity of seal lip damage.

REMOVING CRANKSHAFT AND PINION SHAFT
Remove plunger assemblies. Remove connecting link caps and move the link- crosshead assembly as far forward as possible. On some models, it may be necessary to remove the fluid cylinder body to obtain clearance for crankshaft removal. IMPORTANT: Note the markings on the connecting links and caps; these parts are not interchangeable and must be reassembled in their original positions. Wedge a ¾” board between crankshaft gear and gear case so that crankshaft will be held in place against pinion shaft. Remove both crankshaft bearing caps. Hold crankshaft at ring gear and left-hand link journal (to prevent dropping into bearing bores), remove from gear case by moving crankshaft to right until left end can be swung free. To remove pinion shaft, observe inside of gear case, to see if small sheet metal plates are in front of each bearing. These plates must be removed. Then remove bearing caps.

REPLACING PINION SHAFT AND SHIMMING BEARINGS

After installing the link-crosshead assemblies and moving them toward the fluid end as far as possible, tap righthand pinion shaft bearing cup into position using the bearing cap. Place pinion shaft in position and tap lefthand bearing cup into place. The replace sheet metal plates, if uwed on this model pump.

• Cover shaft keyway with vinyl tape to protect lip of oil seal, slide on the open bearing cap to which has been added approximately .030 shim, tighten the four cap screws to recommended torque.
• Put on other cap using total shim thickness known to be more than needed so that resulting end play is greater than required. Tighten cap screws holding pinion or crankshaft caps to gear case. Rotate pinion shaft back and forth and apply about 15 lbs. axial force to properly seat tapered rollers. Measure end play by using an indicating gage in a manner 
• Subtract recommended end play (.005-.009) from actual end play as found above. This is the amount of shim that must be removed. After excess shim thickness has been removed, replace caps and retighten cap screws. Again measure end play. If end play is not within limits recommended, add or subtract shims as required.

REPLACING CRANKSHAFT AND SHIMMING BEARINGS
Press the bearing cups into the caps. Place one cap into position on the right side with cap screws engaged about one turn; install crankshaft (left end first), then push both bearing caps into place. Extreme care should be exercised to avoid damage to gear teeth, bearings, and link journals. For quiet operation and long life, the crankshaft and bearings must be installed with .003 to .005″ preload; the following procedure will provide an accurate adjustment Before starting, loosen the four cap screws on the pinion shaft bearing cap.

• Place about .045 shim on the right crankshaft bearing cap, tighten the five cap screws.
• Install the other cap without shims, secure with two cap screws positioned exactly
• Torque the two cap screws at 13 ft.-lbs., rotate the crankshaft, retorque the cap screws. Do this three times to properly seat the tapered roller bearings.
• Measure (adjacent to the cap screws) the shim gap remaining between the bearing cap and the gear case.
• The required shim thickness for this cap is equal to the average gap measurement plus the constant listed in the chart below.
• Insert correct shim thickness under left bearing cap and tighten cap screws.
• Install connecting links and caps; note the markings; torque cap screws.
• Check for adequate side clearance of links on crankshaft. Some shims must be moved from one end of the crankshaft to the other until sideways movement of all links can be seen.
• Check torque of cap screws on all bearing caps.

RECONDITIONED CRANKSHAFTS
When the crank throws are only slightly damaged, such as small surface grooves cut part way around the bearing surface, they can sometimes be reconditioned for further use. This can be done by sandpapering and polishing until all ridges are completely removed. The final polishing operation should be with very fine emery cloth. If the surface is badly damaged, the crankshaft can often be salvaged by “metallizing” the crankshaft throw and then regrinding and polishing to the original diameter

SERVICING CONNECTING LINKS
The connecting rod link is furnished with replaceable split sleeve bearing inserts at the crank throw. It is never practical to attempt to re-fit connecting links to the crankshaft bearings by filing or grinding the matting faces of the link cap where it contacts the link. Always be sure that the proper side of the link is placed upward when attaching it to the crankshaft. The upper side contains an oil hole at the crosshead end of the link. This oil hole must be up to allow proper oil feeding to the crosshead pin bushing. the wrist pin is press-fitted into the crosshead and slip-fitted through the bronze bushing. Use arbor press instead of hammering to force the. wrist pin. Check to see if link is free to rotate after the wrist pin is pressed in. Make sure that either side of the wrist pin does not protrude beyond the crosshead.

CROSSHEADANDPLUNGERRODS
Repair parts for the crosshead and piston rod are supplied only as a complete unit. If either of these parts becomes worn it is necessary to replace both the crosshead and piston rod. It is not practical to attempt to tighten a loose piston rod in a crosshead. Under normal conditions a crosshead will not wear nor will the bore of the crankcase wear to the extent that oversize crossheads will be required. If extreme wear does occure, it will be dur to severe damage from the lack of oil or a fairly large metal object scoring the crosshead bore. A clearance of .002″ to .004″ is standard for the crosshead. The parts can wear until considerably more clearance than this exists before harmful operation will occur.

RECOMMENDED TORQUE (Expressed in foot-pounds

SERVICE CHART

Explanation of the service chart

Pump priming is usually not necessary when the pump is installed correctly. However, there are certain unusual conditions which may make it necessary to prime the pump to get the pumping action started. Priming will be required under conditions where it is impossible for the plunger to displace the air in the pump and replace it with water. This could be caused by a high suction lift (high from the water supply to the pump), the valves being stuck on the seat, such as after pumping a sticky fluid, or it might be caused by valves sticking due to extreme corrosion of the valves and seats. A pump will not prime readily if someone has tampered with the valve springs causing them to exert undue pressure of valve plates against the valve seats. When the pump appears to need priming this condition can be checked by pouring water into the cylinder body through one of the valve cap openings or into the pump discharge opening at the same time operating the pump to work the water into the cylinder and valve passages. 2. Frequently a gate valve is installed in the suction line between a tank or pressure line and pump sediment chamber. This valve is usually installed in the line to shut off the supply source for cleaning sediment chamber or for pump repairs If this valve is closed or even partially closed it will interfere with the flow of water to the pump suction to such an extent that the pump will not perform to full capacity. It the valve is partially closed it may cause severe knocking and vibration of the pump because the water cannot flow into the cylinder cavities fast enough. 3. A sediment chamber should be installed in the suction line between the gate valve and the pump suction. The strainers in these sediment chambers are of more than adequate capacity to allow a free flow of the liquid to the pump. However, because of its normal function of collecting sediment the strainer may become severely clogged and in some cases, it will completely stop the flow of liquid to the pump. The length of time the pump may operate before it is necessary to clean the strainer will depend upon the type of liquid pumped. After the pump has been used a short period the operator will soon become familiar with the amount of running time between strainer cleaning.

UNUSUAL CONDITIONS WHICH MAY CAUSE TROUBLE
Pinion shaft breakage on the drive side of the pump may be caused by having the pulley or sprocket positioned too far away from the pump bearing. It may also be caused by a loose drive chain if the pump is chain driven. · If the V-belts have a tendency to wear rapidly, it may be due to having the belt tightener pulley adjusted too far into the belt, throwing a reverse bend in the belt where it passes over the pulley. If very much reverse angle seems necessary to keep the belt tight, other provisions should be made for tightening, such as placing shims under the pump base or otherwise spreading the drive centers enough to take up the belt length. On multiple V-belt drives, a complete set of belts should be installed when making a replacement. Further, all the belts in one set should be checked for length and accurately matched to avoid placing an undue load on any one belt.

D25-8 & D25-8AB INDUSTRIAL PUMP PARTS LIST

D40-8 & D40-8AB INDUSTRIAL PUMP PARTS LIST

WARRANTY

STANDARD LIMITED WARRANTY CENTRIFUGAL & RECIPROCATING PUMPS

Pentair Myers® warrants its products against defects in material and workmanship for a period of 12 months from the date of shipment from Pentair Myers or 18 months from the manufacturing date, whichever occurs first – provided that such products are used in compliance with the requirements of the Pentair Myers catalog and technical manuals. During the warranty period and subject to the conditions set forth, Pentair Myers, at its discretion, will repair or replace to the original user, the parts that prove defective in materials and workmanship. Pentair Myers reserves the right to change or improve its products or any portions thereof without being obligated to provide such a change or improvement for prior sold and/or shipped units. Seals, piston cups, packing, plungers, liners and valves used for handling clear, fresh, nonaerated water at a temperature not exceeding 120ºF are warranted for ninety days from date of shipment. All other applications are subject to a thirty day warranty. Accessories such as motors, engines and auxiliary equipment are warranted by the respective manufacturer and are excluded in this standard warranty. Under no circumstance will Pentair Myers be responsible for the cost of field labor, travel expenses, rented equipment, removal/reinstallation costs or freight expenses to and from the factory or an authorized Pentair Myers service facility. This limited warranty will not apply: (a) to defects or malfunctions resulting from failure to properly install, operate or maintain the unit in accordance with the printed instructions provided; (b) to failures resulting from abuse, accident or negligence; (c) to normal maintenance services and parts used in connection with such service; (d) to units that are not installed in accordance with applicable local codes, ordinances and good trade practices; (e) if the unit is moved from its original installation location; (f) if unit is used for purposes other than for what it is designed and manufactured; (g) to any unit that has been repaired or altered by anyone other than Pentair Myers or an authorized Pentair Myers service provider; (h) to any unit that has been repaired using non factory specified/OEM parts. Warranty Exclusions: Pentair Myers MAKES NO EXPRESS OR IMPLIED WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. Myers SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE. Liability Limitation: IN NO EVENT SHALL Myers BE LIABLE OR RESPONSIBLE FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO ANY Myers PRODUCT OR PARTS THEREOF. PERSONAL INJURY AND/OR PROPERTY DAMAGE MAY RESULT FROM IMPROPER INSTALLATION. Myers DISCLAIMS ALL LIABILITY, INCLUDING LIABILITY UNDER THIS WARRANTY, FOR IMPROPER INSTALLATION. Myers RECOMMENDS INSTALLATION BY PROFESSIONALS. Some states do not permit some or all of the above warranty limitations or the exclusion or limitation of incidental or consequential damages and therefore such limitations may not apply to you. No warranties or representations at any time made by any representatives of Pentair Myers shall vary or expand the provision hereof.

Pentair Myers

• 1101 MYERS PARKWAY
• ASHLAND, OHIO, USA 44805
• 419-289-1144
• WWW.FEMYERS.COM
• Warranty Rev. 12/13

References

• Myers | Municipal Commercial & Industrial Pumps | Pentair

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