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Teaching material
MT 184 Assembly and Maintenance Exercise: Piston Pump
10/2008
MT 184 ASSEMBLY AND MAINTENANCE EXERCISE: PISTON PUMP
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Teaching material
Dipl.-Ing. Klaus-Jürgen Radtke
Dipl.-Geogr. Uta Linke
Version 1.0
i
Subject to technical alternations
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Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technological principles of pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Classification and categorisation of pump types based on operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Designs and operating characteristics. . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 GUNT Practice Line kits and their usage . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Operating characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.1 Pump and system characteristics . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.3 Alteration of the operating point by restriction and variation of speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.4 Operating characteristics of multiple interacting pumps . . . . 20
2.4.5 Intake characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . 21
3 Basics of pump maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Definition Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Reasons for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Detection of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Checking pumps and replacing common wearing parts . . . . . . . . . . 27
3.5 Wearing parts in the pumps from the GUNT Practice Line for assembly and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.6 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.7 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7.1 Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7.2 Shaft and piston rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.7.3 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.7.4 Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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4 Technical description of piston pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.5 Dimensions of the piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.6 Parts drawings and parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5 Assembly and dismantling of the piston pump. . . . . . . . . . . . . . . . . . . . . . 59
5.1 Assembly of the piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.1.1 Assembly phase 1 – Crankshaft (assembly unit 1). . . . . . . . 60
5.1.2 Assembly phase 2 – Connecting rod with piston rod (assembly unit 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1.3 Assembly phase 3 – Packing gland (assembly unit 3) . . . . . 69
5.1.4 Assembly phase 4 – Intake valve (assembly unit 4) . . . . . . . 73
5.1.5 Assembly phase 5 – Pressure valve (assembly unit 5) . . . . 77
5.1.6 Assembly phase 6 – Gearbox (assembly unit 6) . . . . . . . . . 81
5.1.7 Assembly phase 7 – Pump housing (assembly unit 7) . . . . . 91
5.1.8 Assembly phase 8 – Pump . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.2 Dismantling the piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.2.1 Dismantling assembly phase 8 – Pump . . . . . . . . . . . . . . . 107
5.2.2 Dismantling assembly phase 7 – Pump housing . . . . . . . . 110
5.2.3 Dismantling assembly phase 6 – Gearbox . . . . . . . . . . . . . 113
5.2.4 Dismantling assembly phase 5 – Pressure valve . . . . . . . . 116
5.2.5 Dismantling assembly phase 4 – Intake valve . . . . . . . . . . 117
5.2.6 Dismantling assembly phase 3 – Packing gland . . . . . . . . 118
5.2.7 Dismantling assembly phase 2 – Connecting rod with piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.2.8 Dismantling assembly phase 1 – Crankshaft . . . . . . . . . . . 120
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6 Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.1 Spare parts drawing and spare parts list . . . . . . . . . . . . . . . . . . . . . 123
6.2 Worksheet 1: Introduction to the piston pump, page 1 . . . . . . . . . . 130
6.3 Worksheet 2: Design, function and applications of the piston pump, page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.4 Worksheet 3: Identifying causes of faults, page 1 . . . . . . . . . . . . . . 135
6.5 Worksheet 4: Sealing systems, page 1 . . . . . . . . . . . . . . . . . . . . . . 136
6.6 Worksheet 5: Inspection of pumps, page 1 . . . . . . . . . . . . . . . . . . . 139
6.7 Worksheet 6: Servicing of pumps, page 1. . . . . . . . . . . . . . . . . . . . 141
6.8 Worksheet 7: Repairs to pumps, page 1 . . . . . . . . . . . . . . . . . . . . . 143
6.9 Worksheet 8: Wearing parts on the piston pump, page 1 . . . . . . . . 145
6.10 Worksheet 9: Assembling the piston pump, page 1 . . . . . . . . . . . . 147
6.11 Worksheet 10: Piston replacement, page 1. . . . . . . . . . . . . . . . . . . 153
6.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1 . . . . . . . . . . . . . . . . . . . 155
6.13 Worksheet 12: Spare parts ordering, page 1. . . . . . . . . . . . . . . . . . 163
7 Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.1 Spare parts drawing and spare parts list . . . . . . . . . . . . . . . . . . . . . 165
7.2 Worksheet 1: Introduction to the piston pump, page 1 . . . . . . . . . . 172
7.3 Worksheet 2: Design, function and applications of the piston pump, page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
7.4 Worksheet 3: Identifying causes of faults, page 1 . . . . . . . . . . . . . . 177
7.5 Worksheet 4: Sealing systems, page 1 . . . . . . . . . . . . . . . . . . . . . . 178
7.6 Worksheet 5: Inspection of pumps, page 1 . . . . . . . . . . . . . . . . . . . 181
7.7 Worksheet 6: Servicing of pumps, page 1. . . . . . . . . . . . . . . . . . . . 183
7.8 Worksheet 7: Repairs to pumps, page 1 . . . . . . . . . . . . . . . . . . . . . 185
7.9 Worksheet 8: Wearing parts on the piston pump, page 1 . . . . . . . . 187
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7.10 Worksheet 9: Assembling the piston pump, page 1 . . . . . . . . . . . . 189
7.11 Worksheet 10: Piston replacement, page 1. . . . . . . . . . . . . . . . . . . 195
7.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1 . . . . . . . . . . . . . . . . . . . 197
7.13 Worksheet 12: Spare parts ordering, page 1. . . . . . . . . . . . . . . . . . 205
8 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
9 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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1 Introduction
The MT 184 practice kit forms part of the GUNT learning concept for pumpmaintenance, which is designed to aid education and training at trade acad-emies and corporate training centres.
A close link between theory and practice is key to the learning content.
We offer the following products relating to the subject of pump assembly andmaintenance:
This kit includes a piston pump.
Groups of two or three students working with one kit represents an optimalway of learning.
Pumps
Code Product
MT 180 Assembly and maintenance exercise - centrifugal pump
MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump
MT 182 Assembly and maintenance exercise - screw pump
MT 183 Assembly and maintenance exercise - diaphragm pump
MT 184 Assembly and maintenance exercise - piston pump
MT 185 Assembly and maintenance exercise - in-line centrifugal pump
MT 186 Assembly and maintenance exercise - gear pump
Tab. 1.1 Product relating to pump assembly and maintenance
1 Introduction 1
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The following learning content is covered:
The teaching material includes a technical description detailing the basics ofpumps and dealing with the related maintenance.
The pump included in this kit is presented and described. Its assembly anddisassembly is demonstrated.
This section of the teaching material is intended to help tutors in preparingtheir own lessons. They may, of course, select information from it at their owndiscretion to use in their teaching.
The kit also includes prepared exercise sheets for the students, followed bythe relevant solutions.
The appendix includes the complete set of drawings for the pump, in the formof an assembly drawing with parts list, and including all manufacturing draw-ings for the individual components.
We very much hope you enjoy using this GUNT assembly practice kit, andwe wish you success in your important task of providing students and appren-tices with an introduction to the basic principles of the technology.
Learning content / Exercises
Design and function of a piston pump
Assembly and disassembly, including for maintenance purposes
Replacing components (e.g. seals)
Reading and understanding engineering drawings and operating instructions
Comparing different pumps(together with an additional kit forming part of this learning concept)
Tab. 1.2 Learning content / Exercises
1 Introduction 2
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2 Technological principles of pumps
This chapter is designed to provide basic information for the following assem-bly and maintenance exercises from GUNT.
Wherever liquids are transported, produced or required to be supplied,pumps are deployed. The demands which they must met vary widely. A vastrange of fluids has to be conveyed, from highly sensitive pharmaceuticals,through large volumes of cooling liquid in power stations, to viscous chemicalproducts.
A wide variety of pumps have been developed over time for industrialapplications.
Not all pumps are mentioned in the following. Our outline presents astructured guide to the most common types of pump.
Code Product
MT 180 Assembly and maintenance exercise - centrifugal pump
MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump
MT 182 Assembly and maintenance exercise - screw pump
MT 183 Assembly and maintenance exercise - diaphragm pump
MT 184 Assembly and maintenance exercise - piston pump
MT 185 Assembly and maintenance exercise - in-line centrifugal pump
MT 186 Assembly and maintenance exercise - gear pump
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2.1 Classification and categorisation of pump types based on operating principle
Pumps are fluid-flow machines which dictate how processes operate - that isto say, they ensure that flow takes place within systems.
In practice, pumps are often named after the liquid they pump or theirpurpose, such as milk pumps or cooling pumps. However, technicians andfitters can more easily identify their design when they are named accordingto their operating principle.
Fig. 2.1 Pump types
OscillatingSelf-priming
(Displacement device moves back and forth along an axis)
Normally priming(Not carrying gas, pumping from low level restricted)
RotatingSelf-priming
(Displacement device rotates in the pump body)
Self-priming(Carrying gas,
pumping from low level possible)
Piston pumps
Diaphragm pumps
Centrifugal pumps
Multi-stagecentrifugal pumps
Inline pumps
Gear pumps
Screwpumps
Side-channelpumps
Positive-displacement pumps
(Medium conveyed bydisplacement device)
Centrifugal pumps(A gyro causes
centrifugal forces to act on the medium)
Engines(Flowing medium drives machine)
Turbines
Machines(Machine drives a flowing medium)
Pumps
Fluid-flow machines
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2.2 Designs and operating characteristics
The following table sets out the designs and operating characteristics of themost common positive-displacement pumps.
The piston pump incorporates an oscillating piston which is routed into a cylinder. The piston moves on an axis. The pump body is blocked by intake and pressure valves. A stroke gear drives the piston, which enlarges or reduces the pump chamber on every stroke.
By enlarging the pump chamber, the pumped fluid is drawn in by way of the intake valve. After a change of stroke the pump chamber is reduced and the pumped liquid is displaced by way of the pressure valve.
The diaphragm pump contains an elastomer diaphragm which is clamped into the pump housing. The oscillation is transferred from the stroke gear to the diaphragm by way of a thrust rod. The fluid feeds in and out by way of the valves, frequently executed as ball valves.
The method of operation is the same as the piston pump, with the diaphragm acting as the displacement device.
The gear pump contains two opposite rotating rigid or elastic gear wheels. The pump body is not closed off by valves.
The liquid is pumped by the rotating gear wheels from the intake to the delivery side in the gaps between the teeth along the pump wall. The gear meshing and narrow gaps between the rotor and housing minimise the reflux.
The screw pump consists of two or more spindles with helical splines which rotate inside a correspondingly shaped housing. The pump body is not closed off by valves.
The liquid is pumped axially in the free screw turns from the intake to the delivery side.
Here too, as in the case of the gear pump, the sealing from the delivery to the intake side is provided by narrow gaps.
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The following table sets out the designs and operating characteristics of themost common centrifugal pumps.
The centrifugal pump contains a rotating, enclosed impeller with backward facing blades. The intake port is axially aligned to the pump shaft. The delivery port is aligned radially upwards.
The rotating impeller inside the pump body causes centrifugal forces to act on the pumped liquid. The liquid thrown out to the circumference of the pump by this flows out of the pump through the delivery port.
The multi-stage centrifugal pump is similar in design and action to the centrifugal pump. The difference is that is features multiple impeller arranged in a row on a shaft.
The pumped liquid passes from the intake port via the rotating impeller through a fixed guide channel to the next impeller, and so on, until it reaches the delivery port. The multistage impeller layout means the pump attains higher delivery heads.
The inline centrifugal pump is similar in design and method of operation to the centrifugal pump. Its intake and delivery ports are along one axis however, though here too the feed to the pump flows axially by way of an appropriately shaped housing. The inline pump is used in straight pipelines.
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Other special centrifugal pump designs
The side-channel pump contains a rotating starshaped open impeller with radially running vanes. It rotates inside a pump housing featuring a side channel which narrows from the inlet to the outlet.
The energy transfer acts on the medium by means of an exchange flow of the liquid in the impeller with that in the side channel. The side channel pump thus operates continuously with a self-priming effect, whereas the centrifugal pump is not self-priming.
The canned motor pump is similar in design and action to the centrifugal pump. It is leakage-free, as it requires no shaft seal. The drive of the canned motor pump is located practically inside the pump housing, and the pumped liquid flows around it.
The magnetic clutch pump is similar in design and action to the centrifugal pump. It is leakage-free and requires no shaft seal.
The magnetic clutch pump is driven by a non-contact magnetic clutch. The magnet on the pump shaft is inside the pump housing. It is separated from the magnet on the motor shaft by a tube.
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2.3 GUNT Practice Line kits and their usage
The GUNT Practice Line kits for assembly and maintenance exercisesinclude the following pumps:
MT 180 – Centrifugal pump
Centrifugal pumps are in widespread use, and are primarily used to pumpfluid media. Their applications include in shipbuilding, industry and watersupply.
Fig. 2.2 Toolkit with parts set and pump
Fig. 2.3 Sectional drawing of the centrifugal pump
2 Technological principles of pumps 8
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MT 181 – Multi-stage centrifugal pump
The multi-stage centrifugal pump is modular in design, and is used to pumpfluid media at higher delivery pressures. It is used in water supply and inindustry.
Fig. 2.4 Toolkit with parts set and pump
Fig. 2.5 Sectional drawing of a similar multi-stage centrifugal pump
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MT 182 – Screw pump
Screw pumps are primarily used to transport viscous media such as lubricat-ing oil, plant oil, glycols and polymers. Their applications include lubricationsystems for diesel engines and transmissions, as well as in hydraulicsystems.
Fig. 2.6 Toolkit with parts set and pump
Fig. 2.7 Exploded-view drawing of the screw pump
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MT 183 – Diaphragm pump
Diaphragm pumps are absolutely leakage-free and, provided appropriatematerials are selected, are particularly well suited to pumping aggressivefluids such as acids and caustic in chemical engineering applications.Diaphragm pumps are often used for volumetric metering, as meteringpumps.
Fig. 2.8 Toolkit with parts set and pump
Fig. 2.9 Sectional drawing of the diaphragm pump
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MT 184 – Piston pump
Piston pumps are used primarily to transport fluids at high delivery pressuresand low flow rates. Typical applications include pumping drinking water anddomestic water in residential areas, in agriculture, onboard ships and inindustry.
Fig. 2.10 Toolkit with parts set and pump
Fig. 2.11 Drawing of the piston pump
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MT 185 – Inline centrifugal pump
In-line centrifugal pumps are a sub-category of centrifugal pumps. Inlinepumps are installed in straight pipelines. They are required in applicationsincluding water supply, watering and sprinkler systems, and in heating engi-neering.
Fig. 2.12 Toolkit with parts set and pump
Fig. 2.13 Exploded-view drawing of the in-line centrifugal pump
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MT 186 – Gear pump
Gear pumps are of the rotating positive-displacement pump category, andare characterised by pulsation-free delivery at operating pressures up to40bar. High-viscosity media such as oils, paints and adhesives can bepumped.
Fig. 2.14 Toolkit with parts set and pump
Fig. 2.15 Exploded-view drawing of the gear pump
2 Technological principles of pumps 14
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2.4 Operating characteristics of pumps
Alongside preventive maintenance, repair work forms a key part of generalservice operations. Damage to pumps can be traced back to incorrect oper-ation in more than 50% of cases.
It is advantageous for the assembly personnel to have basic knowledge ofhow the pump operates and are aware of how to use the pump correctly.
2.4.1 Pump and system characteristics
The delivery capacity of a pump is indicated by the pump’s characteristiccurve. The delivery rates are measured on the test stand at the respectivedelivery pressures. The pump measurement data is depicted in the form of acharacteristic curve. Usually the delivery head is given in place of the deliv-ery pressure (as a result the characteristic curves of centrifugal pumps arenot dependent on the density of the pumped liquid).
In the case of centrifugal pumps the dependency of the delivery rate on thehead is marked: As the head rises, the delivery rate decreases significantly.By contrast, the delivery rate of positive-displacement pumps remains virtu-ally constant as the head rises.
In the case of positive-displacement pumps, it must be ensured that thepermissible operating pressure is not exceeded. Overflow valves arefrequently used for this.
Fig. 2.16 Characteristic curve fora centrifugal pump
Fig. 2.17 Characteristic curve fora positive-displacement pump
Delivery QDelivery Q
Hea
d H
Hea
d H
2 Technological principles of pumps 15
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Operation of the positive-displacement pump with the overflow valve(partially) open is depicted in the horizontal segment of the curve (see Fig.2.17).
The graph gives an indication of the delivery capacity of the pumps, thoughit provides no information on the delivery data actually achieved.
An often cited problem when operating pumps is that the pump does notreach the necessary pressure. Generally speaking, pumps only deliver mate-rial; the associated pressure is caused by the system.
The system operating data can likewise be measured and depicted graphi-cally in the system characteristic curve. As the delivery rate increases, thesystem pressure - determined by practical calculation - rises.
Fig. 2.18 System characteristic curve
Delivery Q
Hea
d H
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2.4.2 Operating point
The actual delivery data result from the interaction of the pump and thesystem.
If the pump and system curves are plotted on the same diagram, the point atwhich the curves intersect is the operating point.
So if the operating data do not conform to the specification, the technicianshould first check and calculate the correct operation of the pump in thesystem. This should be done on initial commissioning and every time thesystem is modified.
Fig. 2.19 Operating point (1) of anormally priming centrifugalpump
Fig. 2.20 Operating point (1) of apositive-displacement pump
Delivery QDelivery Q
Hea
d H
Hea
d H
1
1
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2.4.3 Alteration of the operating point by restriction and variation of speed
In practice, restriction is frequently used to set the desired delivery rate. Theflow is restricted by partially closing a valve on the delivery side of the pump.This results in a new system curve with a steeper rise. The new operatingpoint 2 is the point of intersection of the new system curve with the pumpcurve. Or in other words: The operating point has shifted along the pumpcurve from 1 to 2.
While the delivery rate decreases as the head rises on a centrifugal pump,the delivery of a positive-displacement pump remains constant as thepressure rises.
Fig. 2.21 Shift in operating point from (1) to (2) by restriction for a normally priming centrifugal pump
Fig. 2.22 Shift in operating point from (1) to (2) by restriction for a positive-displacement pump
Delivery QDelivery Q
Hea
d H
Hea
d H
1
2
2
1
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A common method of shifting the operating point of a pump is to vary thespeed. The speed is varied by means of an adjuster gear or a frequencyinverter. This produces a new pump characteristic curve.
The diagrams show an increase in speed from n1 to n2 for both pump types(see Fig. 2.23 and Fig. 2.24). In the case of the centrifugal pump, the pumpcurve moves upwards, while for the positive-displacement pump it shifts tothe right.
In both diagrams the operating point shifts upwards along the system curve.That is to say, higher heads and delivery rates are produced as the speedincreases.
Fig. 2.23 Influence on the pump characteristic of a variation in speed for a normally priming centrifugal pump
Fig. 2.24 Influence on the pump characteristic of a variation in speed for a positive-displacement pump
Delivery QDelivery Q
Hea
d H
Hea
d H
n1
n2
n1
n2
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2.4.4 Operating characteristics of multiple interacting pumps
Operation of multiple pumps simultaneously in a system is quite common,and in many cases essential in order to conform to extreme operating speci-fications.
If multiple pumps are configured in parallel, the delivery rate is increased. Ifpumps are configured in series (one behind the other), the delivery headsare added together.
The pump industry has made use of these properties and developed anumber of designs accordingly.
Multi-flow pumps achieve high delivery rates, multi-stage pumps achievehigh heads.
Fig. 2.25 Parallel configuration Fig. 2.26 Series configuration
Fig. 2.27 Multi-flow pump, sectional view and delivery principle
Fig. 2.28 Multiple-stage pump, sectional view and delivery principle
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2.4.5 Intake characteristics of pumps
Attention must be paid to the intake characteristics of the pumps. A distinc-tion is made between selfpriming and nonselfpriming pumps.
The normally priming centrifugal pump is a non-self-priming pump. It is notcapable of pumping a gaseous medium out of the pump body. It must alwaysbe ensured that a liquid is fed in from a higher level, or where the feed is froma lower level, the liquid head does not collapse, such as due to the use of footvalves on the intake side.
Fig. 2.29 Infeed of a pump system for a normally priming pump
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Self-priming pumps include side channel pumps (see chapter 2.2, page 5).They are capable of pumping gases. However, the pump body must alwaysbe filled with liquid for this to happen. That is why the intake and delivery portson side channel pumps always point upwards.
Most positive-displacement pumps are self-priming. The displacementdevice is able to compress the gas and displace it out of the pump body. Forthis to happen, however, the pump must be partially filled with liquid, becauseonly wetted valves close exactly such that no reflux is possible. This alsoapplies to rotating positive-displacement pumps, of which the wetted gapsrestrict reflux.
Fig. 2.30 Intake of a pump system for a self-priming pump
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3 Basics of pump maintenance
3.1 Definition Maintenance
All pump operators should maintain their pumps in accordance with the main-tenance and operating instructions issued by the manufacturers. Mainte-nance is the umbrella term for inspection, servicing and repair (see Fig. 3.1).A log book or machine file should be set up for each pump unit, indicating thecurrent status and the repair work carried out to date.
Fig. 3.1 Maintenance
Replacement,Correction
With the system running and at stand
still based oninspection instructions
Only with the system stopped, based on
specific work order and after careful preparation
Only withsystem stopped
according tomaintenance instructions
MAINTENANCE TO DIN 31051
Inspection RepairsServicing
Recording and assessment of the
current actual status
Restoration of the specified status
Preservation of thespecified status
Measurement,Testing,
Diagnosis
Cleaning,Lubrication,Adjustment
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3.2 Reasons for maintenance
Pumps are required for the operations of many manufacturing systems. If thepumps are malfunctioning, there is a risk of production outages. Appropriatemaintenance is a key factor determining the productivity of operations.
Complete replacement of the pump is possible in the event of a defect,though it is not always essential and, especially, is not necessarily cost-effec-tive. Carrying out preventive maintenance and servicing, as well as repairs,is advantageous. A number of reasons are cited by way of example.
• The cost of purchasing a mid-sized industrial pump is considerable. Theannual cost of wearing parts amounts to around 10% - 20% of thepurchase price of the new pump.
• Holding a complete replacement pump in stock is inefficient and expensivefor many businesses. It is, however affordable, and advisable, to holdstocks of key pump spares.
• The delivery lead times for complete pumps are usually lengthy, whereasspares can be supplied from suppliers’ central stores at short notice.
• Fig. 3.2 shows that routine maintenance of pumps (2) results in lower costsin the medium and long term than complete replacement of pumps (1).
Fig. 3.2 Total cost, comparison of replacement (1) and maintenance (2)
Service life
Cos
t 1
2
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3.3 Detection of faults
Many factors need to be considered in order to ensure optimised, trouble-freeoperation of pumps. Nevertheless, faults will routinely occur. A number ofbasic points need to be observed in order to assess faults and their causes:
• The specifications of the delivery medium need to be considered in orderto ensure long service life of the pumps. The material durability of thepump components and seals must be ensured. The design and construc-tion of the pump must be attuned to the specific pumping requirements.
• Most pumps are driven by electric motors. Attention must be paid tocorrect dimensioning and selection.
• Incorrect electrical connections and setting the incorrect direction ofrotation are often sources of faults resulting in production problems.
• As a general rule applicable to all pumps, lengthy periods of dry runningshould be avoided, as this would substantially shorten the service lives ofthe shaft seal, piston seal and valves. The delivery medium providesadditional lubrication of those components. This principle is illustrated bythe example of the floating ring seal in Fig. 3.3.
There must always be a liquid film between the contact faces of a floating ringseal.
Fig. 3.3 Floating ring seal with liquid film
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During inspection of the pump, checks should be made regularly while thepump is running to ensure early detection of faults, focussing in particular onthe following points:
• Leakage
• Noise
• Smooth running
• Temperature
• General condition
The reasons for pump faults are many and varied.
System-related disturbances such as pressure surges should be avoided oreliminated. Incorrectly switching system valves may stop the pumped liquidto an extreme degree, causing overlaid liquid waves to form which result inpressure surging as far as into the pump.
Trapped foreign bodies cause significant damage inside the pump.Deformed shafts, destroyed bearings and valves, as well as scraping impel-lers, are the consequences of such disturbances. Even tiny abrasive particleswill cause long-term damage to the pump and the seals.
The occurrence of cavitation is a system fault which needs to be prevented.
If the infeed line to the pump is incorrectly dimensioned, it is possible that avacuum will created in the intake port, causing the medium to boil. Theincrease in pressure in the pump causes the boiling bubbles to implode,thereby destroying the housing and impeller.
Fig. 3.4 Cavitation damage to a pump impeller
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3.4 Checking pumps and replacing common wearing parts
In accordance with the service intervals specified in the manufacturers’ main-tenance instructions, which are additionally dependent on the specific oper-ating conditions, it is advisable to check pumps about once a year.
Bearings
The operating instructions specify that the lubricant should be changed onpumps with an enclosed gear and bearing unit.
Modern-day greased bearings are lifetime-lubricated, and merely need to bechecked for smooth running.
Shaft seals
Packing glands and floating ring seals are checked for leaks and wear.
Glands can be adjusted, if still possible. The gland packing should bereplaced after about 2000 operating hours.
The service lives of the floating ring seals are considerably longer. They arereplaced in full if worn.
Couplings
Pumps coupled to their drives by flexible couplings should be checked forflush coupling. The power-transmitting components should be checked forwear and replaced as necessary.
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Pump internals
The pumps should be opened and their internals checked for wear andcorrosion at the specified servicing intervals.
In the case of centrifugal pumps, as well as the shaft seal the static seal ringmust be checked and replaced if worn.
The valves of reciprocating pumps, including their sealing faces, should bechecked. Piston rings and packing should be checked for wear, and theplungers and sleeves checked for scoring.
Fig. 3.5 Pump unit with listed wearing part groups
20Pump internals
Bearing Coupling
Shaft seal
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3.5 Wearing parts in the pumps from the GUNT Practice Line for assembly and maintenance
It should be stated by way of preamble that, according to the state of the artin centrifugal pumps, bearings are no longer classed as wearing parts.
MT 180 – Centrifugal pump
MT 181 – Multi-stage centrifugal pump
Fig. 3.6 Sectional drawing of the centrifugal pump
Fig. 3.7 Sectional drawing of a similar multi-stage centrifugal pump
Shaft seal(gland)
Housing seal
Housing/stage sealPacking gland Floating ring seal
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MT 182 – Screw pump
MT 183 – Diaphragm pump
The wearing parts mentioned should be replaced during servicing.
Fig. 3.8 Exploded-view drawing of the screw pump
Fig. 3.9 Sectional drawing of the diaphragm pump
Floating ring seal
Housing sealHousing seal
Valves
Oil filling
Diaphragm
Journal bearing
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MT 184 – Piston pump
MT 185 – Inline centrifugal pump
Wear is to be expected on the parts marked, necessitating replacement ofthem.
Fig. 3.10 Drawing of the piston pump
Fig. 3.11 Exploded-view drawing of the in-line centrifugal pump
Piston sealOil filling
Piston rod seal
Valves
Housing seal Floating ring seal
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MT 186 – Gear pump
Any well organised maintenance department should hold stocks of thewearing parts on the various pumps mentioned in this chapter.
Fig. 3.12 Sectional drawing of the gear pump
O-rings
Floating ring seal
Housing sealJournal bearingWear disc
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3.6 Shutdown
In systems in which uninterrupted running of pumps is extremely important,such as in power stations or onboard ships, replacement units are installedfully piped-up as standby units. This allows servicing or repairs to be carriedout during live operation, by switching to the standby unit.
In most production environments, maintenance can only be carried out duringproduction downtimes - that is, at partial or complete standstill. The pumpsshould be integrated into the system in such a way that short-interval servic-ing can be carried out without removing them. That is to say, they must beeasily accessible for inspection and servicing. On the pump intake side andthe delivery side stop valves should be installed.
In the case of positive-displacement pumps, the drive unit is first shut down.Immediately after the pump stops the delivery-side valve is closed, then theintake side is closed. If non-return valves are installed, they automatically actas stop valves. So installed non-return valves on the delivery side, for exam-ple, prevent possible reflux to the pump.
In the case of centrifugal pumps, the delivery-side valve is first closed, thenthe drive is shut down, and then the intake side is closed.
Before opening the pump, the pump and the connected piping system mustbe drained. This can be done either by way of sealing plugs or by carefullydetaching the pipe fittings.
If the pump unit is removed completely from the system for major mainte-nance work, the safety guidelines issued by the drive manufacturers mustadditionally be followed.
Fig. 3.13 Installation with standby pump
Fig. 3.14 Single pump with stop valves
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3.7 Repairs
Whereas during servicing parts are usually replaced following checking andas required, during repair complete wearing parts or defective componentsare replaced after predetermined operating cycles. These cycles are eitherspecified by the manufacturers or they are determined by the identifiedcondition of parts at the various maintenance intervals.
It is advisable to schedule every second to third service as a repair operation.
3.7.1 Static seals
Flat seals and O-rings used for sealing between metal components and toprevent escape of liquid from the pump body are replaced completely. Theirlocations include at the connection fittings and on the housing covers, floatingring seals, shaft sleeves and valves.
Procedure:
• Dismount the pump
• Remove the seals and dispose of them
• Clean the parts
• Install the new seals during reassembly
• Avoid mechanical damage. Ensure cleanliness. Grease seals where necessary.
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Fig. 3.15 O-rings in a centrifugal pump
Static seals
Static seals
Static seal
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3.7.2 Shaft and piston rod seals
The most varied stresses on seals in pump engineering occur in the sealingof shaft and piston rod feed-throughs. These seals must act between areassubject to different pressures, and are subject to the demands of a widevariety of media, as well as having to withstand additional physical strainscaused by rotating shafts or oscillating piston rods. These types of seal areknown in engineering as dynamic seals. Operators expect reliable sealing,with minimal leakage, over a long service life. The shaft seals in particularshould be preventively replaced during scheduled repair work, because ofthe extreme stresses to which they are subject.
Fig. 3.16 Example of a piston rod seal
Fig. 3.17 Example of a shaft seal
Piston rod seal
Shaft seal
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A tried and proven method of sealing shafts is by means of soft packingglands.
This packing consists of a woven cord made principally of solid fabrics whichis inserted in the packing space between the shaft and the housing, where itis deformed by an axial force and so moulded to the surfaces it is intended toseal.
To seal the pump shaft, packing glands (1) are used. These are provided ina wide range of materials and designs depending on the pump application.To protect the shaft, a shaft sleeve (2) is installed. Locking rings or ancillaryglands (3) hold the packing in place. The gland press (4) compresses thepacking by way of screw fittings. Correct functioning demands careful assem-bly and commissioning.
Fig. 3.18 Example of a gland Fig. 3.19 Packing gland packing
1
2
4
3
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When packing a new gland the following points need to be considered:
• Correct choice of packing based on quality and dimensions
• Completely remove old packing residues (3)
• The shaft protective sleeve (7) must be free of surface damage
• Insert the packing (3) with offset interfaces
• Use of sharp tools will damage the gland
• Tighten the gland press (5) by screws after inserting the packing, thenslacken it slightly
• The pump shaft (2) must be loose enough to be turned slightly by hand
Fig. 3.20 Packing gland of a centrifugal pump, sectional view with zoom
Item Name
1 Washer
2 Shaft
3 Packing gland packing
4 Locking ring
5 Packing gland press
6 Stud bolt with hexagonal nut
7 Shaft sleeve
8 Housing cover
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• Only tighten up the gland press after a run-in time of about 20-30 minuteswith leakage of 50-100 drops per minute
• Adjust the gland to the required leakage rate of 3 drops per minute
To seal shaft lead-throughs which are subject to high stresses, floating ringseals are the most advantageous option nowadays. They are available in awide range of designs, dimensions and frictional material pairings. Correctlyselected, fitted and operated floating ring seals will permit longer-lastingoperation of rotating positive-displacement and centrifugal pumps, with lessleakage, then packing glands.
Floating ring seals are contact seals which create a yielding seal connectionbetween stationary and rotating contact faces. Between the contact faces isa film of liquid, which assumes a stable position due to the centrifugal forceoccurring during rotation. The floating ring seal is sealed against the housingby means of static elastomer seals (1). The floating ring (2) rotating with theshaft is held axially in place relative to the counter-ring (4) fixed in the housingby a spring (3). The contact faces thus automatically adjust axially. Even highpressures can be controlled by means of hydraulic relief.
Fig. 3.21 Drawing of a floating ring seal
13 2 4
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Procedure for replacing the floating ring seal on a centrifugal pump shownbelow:• Shut down the pump
• Open the pump cover (1)
• Slacken the impeller nut (2)
• Detach the impeller (3) from the shaft
• Remove the floating ring (4) from the shaft
• Pull the counter-ring (5) out of the housing using a suitable implement
• Assemble in the reverse order of removal
Fig. 3.22 Floating ring seal
Fig. 3.23 Example of replacing a floating ring seal on a centrifugal pump
4 1
2
3 5
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In view of the wide range of floating ring seal designs and pump versions,methods of removal and fitting vary. The principle illustrated here is that appli-cable to the most frequently used centrifugal pump.
The piston rod sealing in oscillating motions of the piston rods and plungersof the piston pumps is achieved by using packing glands, lipped rings,grooved rings (1) and conical rings held in support rings (2). The design andmaterials must always be selected to match the given operating conditions.Spring-loaded (3) seals, for example, offer uniform pre-tension, low frictionand so longer service lives.
The method of removal and fitting depends on the specific pump version anddesign. The manufacturers’ fitting instructions are useful in this context, andshould be followed.
Fig. 3.24 Drawing of a piston rod seal
1 3 2
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The same is true of the piston seals. Replacing piston rings and pistonsleeves forms part of the essential scheduled repair routine. Some designvariants are shown in Fig. 3.25.
Fig. 3.25 Examples of piston seals
Piston with leather/rubber sleeves
Piston with metal seal rings
Piston with hemp stricks
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3.7.3 Valves
Positive-displacement pumps such as reciprocating pumps and diaphragmpumps seal off the delivery space by means of intake and delivery sidepressure valves. They open due to the resultant pressure difference on everystroke and close due to their intrinsic mass or by additional spring force.
The valves of the smaller diaphragm pumps, used as metering pumps in thechemical industry, are executed as ball valves. Owing to the more preciseeffect achieved, twin ball valves are often installed. They are replaced bysimply unscrewing the valve unit out of the housing.
The valves of the piston pumps may be executed as weight or spring-loadeddisc valves.
The sealing faces are mostly metallic, and correspondingly sensitive.
After being individually removed, the discs are replaced. The valve seats arechecked and re-milled or lapped as necessary. In the case of valves with anadditional elastomer sealing disc, only the disc needs to be replaced, and thesmooth running checked.
Fig. 3.26 Twin ball valve of a diaphragm pump
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3.7.4 Spare parts ordering
Maintenance work should generally be carried out on a routine basis inaccordance with the maintenance instructions and safety rules laid down bythe manufacturers. Key parts should be replaced at the maintenance inter-vals indicated in the operational or machine log. Arrangements should bemade for parts to be procured from the supplier in advance.
Every pump has a rating plate affixed to it by the manufacturer. The ratingplate indicates the manufacturer’s name, the pump model and serial number.The data is often also imprinted on the housing, so the information is stillavailable even if the rating plate comes off. Based on this information, theexact technical and material specification can be identified.
Fig. 3.27 Examples of disc valves
Spring-loaded with flat seat and seal ring
Spring-loaded with flat seat Weighted with conical seat
3 Basics of pump maintenance 44
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The details shown in Fig. 3.29 need to be quoted to the supplier when order-ing spares, so as to ensure the correct parts are supplied:
Fig. 3.28 Example of a housing with imprinted model and serial number
Fig. 3.29 Information for spare parts ordering, e.g. identified from rating plate, parts drawing or parts list
1. Pump model
2. Serial number
3. Part name
4. Item number on parts list
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4 Technical description of piston pump
4.1 Description
Piston pumps are used primarily to transport fluids at high delivery pressuresand low flow rates.
At constant speed, the volumetric flow also remains constant at differentpressures. A air chamber built-in to the pump damps the pressure spikeswhich occur on each stroke.
The pump presented here is a double-acting piston pump, which means thateach stroke is simultaneously an intake and a delivery stroke.
The pump incorporates a safety valve, so that if the pressure rises too high aportion of the flow is returned to the intake side.
Typical applications of piston pumps include pumping drinking water anddomestic water in residential areas, in agriculture, onboard ships and inindustry and at commercial garden centres.
Fig. 4.1 Piston pump
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4.2 Mode of operation
The piston pump is driven by way of a pulley and a V-belt by an electric motor.On every revolution, the crankshaft acts by way of the connecting rod and thecrosshead on the piston (1) which is mounted on the end of the piston rod.This stroke motion causes the piston to move back and forth in the cylinderbushing (2).
On every stroke the piston (1) enlarges and reduces the size of the deliverychamber. In the enlarging delivery chamber a negative pressure is created,causing the pressure valve (3) to close and liquid to flow via the intake valve(4) into the delivery chamber. In the reducing delivery chamber the pistonpresses the liquid via the pressure valve out of the pump body, while theintake valve is pressed closed. The piston pump investigated here has adelivery chamber on each side of the cylinder bushing. The pump is double-acting, since on every stroke it simultaneously draws in on one side anddisplaces on the other.
If the pressure on the delivery side (5) of the pumps is too high, the built-insafety valve (7) opens and the liquid flows inside the pump back to the intakeside (6).
Fig. 4.2 Delivery principle of a double-acting piston pump
Item Name
1 Piston
2 Cylinder bushing
3 Pressure valve
4 Intake valve
1
4
3
2
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The piston pump is self-priming. It must, however, be primed prior to initialcommissioning.
The pump delivery is independent of the direction of rotation of the drive.However, optimum lubrication of the gearbox can only be effected in thedirection indicated by the arrow on the pump.
Fig. 4.3 Delivery principle of the piston pump
Item Name
3 Pressure valve
4 Intake valve
5 Delivery Side
6 Intake side
7 Safety valve
7
3 4
65
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4.3 Layout
The layout of the piston pump is shown in the drawings (see chapter 9, page209). The pump consists of the following main components:
• Air chamber with safety valve
• Pump housing with valves
• Piston
• Gland
• Crankshaft
• Crosshead
• Piston rod
• Gearbox housing
Fig. 4.4 Component assemblies of the piston pump
2
1
4765
8
3
Item Name Item Name
1 Air chamber with safety valve 5 Crankshaft
2 Pump housing with valves 6 Crosshead
3 Piston 7 Piston Rod
4 Packing gland 8 Gearbox housing
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The motor is mounted on the pump unit by clamp rails.
The crankshaft, the connecting rod and the crosshead are automaticallylubricated in the gearbox housing by circulating oil on every rotation.
The piston rod is sealed off from the delivery chamber by a packing gland.
The sleeved piston made of NBR rubber runs in a stainless steel cylinderbushing.
The two delivery chambers each contain two disk valves with valve rubberplates.
The delivery side of the pump is executed as a air chamber, with a built-insafety valve.
4.4 Technical data
Pump model: PM 10
Power consumption: max. 0,37 kW
Max. capacity: 1000 ltr/h
Max. delivery pressure: 6 bar
Motor speed: 1450 rpm(driven by V-belt)
Intake connection: 1 “
Pressure connection: 1 “
Pump materials:
Pump body: GG20
Valves: Brass (CuZn39Pb3)
Cylinder bushing: X6CrNi18-10
Piston: NBR
Piston rod seal: PTFE saturated packing rings
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4.5 Dimensions of the piston pump
Fig. 4.5 Dimensions
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4.6 Parts drawings and parts lists
Fig. 4.6 Spare parts drawing for the piston pump
83, 8
7
81, 8
2
79, 8
084
, 85
8779
, 80
85, 8
6
8
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Fig. 4.7 Spare parts drawings for the gearbox
19
6
22
21
4, 23
16
11
3 - 15
8
20
10
3435 14
171833
2
321227913 29282657 1 30,31 24 25
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Fig. 4.8 Spare parts drawings for the pump housing
4245 63 43
4060
51
50, 5
2, 5
3
59
39
65
47
4861
7462
46, 7
776757372
4767
6658
41
54 68
69
7071
4457
58
3849
373664
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Item Quantity
Unit Name Item number / Standard
Comments
1 1 Piece Connecting rod MT184.10.04.001
2 1 Piece Packing gland housing MT184.10.05.002
3 1 Piece Crankshaft MT184.10.03.001
4 1 Piece Bearing cover, open MT184.10.10.001
5 1 Piece Gearbox housing MT184.10.09.001 EN-GJL-200
6 1 Piece Bearing cover, closed MT184.10.09.002 EN-GJL-200
7 1 Piece Gearbox cover MT184.10.09.003 DOC04
8 1 Piece Base plate MT184.10.09.004 S235JR
9 1 Piece Oil splash guard MT184.10.09.005 DOC04
10 1 Piece Packing gland seal MT184.10.09.006 SBR/B-870M
11 2 Piece Bearing cover seal MT184.10.09.007 SBR/B-870M
12 1 Piece Oil stripper MT184.10.09.008 60NBR693 SW
13 1 Piece Oil plug MT184.10.09.009 CuZn39Pb3
14 1 Piece Duo-piston PM10 Simirit
15 1 Piece Disk spring DIN 6888-5x7,5
16 8 Piece Hexagon nut ISO 4032-M6 8
17 2 Piece Hexagon nut ISO 4032-M8 8
18 1 Piece Spring ring DIN 127-A-8 A2
19 6 Piece Hexagon screw ISO 4017-M6x12 8.8
20 4 Piece Rubber buffer 500029 GMT
21 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
22 2 Piece Angled oiler with nut G1/8 Spike
23 1 Piece Radial shaft seal DIN 3760-A-16x35x7
NBR
24 2 Piece Grooved ball bearing DIN 625-6202
25 1 Piece Grooved ball bearing DIN 625-6203
Tab. 4.1 Spare parts list
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26 1 Piece Crosshead MT184.10.04.002 EN-GJL-200
27 1 Piece Piston Rod MT184.10.04.003 X14CrMoS17
28 1 Piece Straight pin ISO 8734-12x35 C1
29 1 Piece Hexagon nut ISO 4032-M8 8-A2
30 1 Piece Hexagon screw ISO 4017-M6x25 8.8
31 1 Piece Hexagon nut ISO 4032-M6 8-A2
32 1 Piece Packing gland screws MT184.10.05.002 CuZn39Pb3
33 1 Piece Brass washer MT184.10.05.003 CuZn37F30
34 1 Piece Gland packing 00.2251 Spike
35 1 Piece Lip seal ISO 4032-M8 A2-70
36 1 Piece Lock nut MT184.10.09.002 CuZn39Pb2
37 1 Piece Knurled screw MT184.10.08.003 CuZn39Pb3
38 1 Piece Cap MT184.10.08.004 NBR
39 1 Piece Pump housing MT184.10.06.001 EN-GJL-200
40 1 Piece Cylinder cover MT184.10.06.002 EN-GJL-200
41 1 Piece Air chamber MT184.10.06.003 EN-GJL-200
42 1 Piece Water plug MT184.10.06.004 CuZn39Pb2
43 1 Piece Air chamber stud bolt MT184.10.06.005 9SMn28K
44 1 Piece Cylinder pipe MT184.10.06.006 X6CrNi18-10
45 1 Piece Cap nut DIN 1587-M12 CuZn39Pb3
46 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
47 1 Piece Membrane safety valve SV.01-065.7,5 F3000.4
Spike
48 2 Piece Straight flange G1“ MT184.10.06.010 EN-GJL-200
49 1 Piece Poppet valve body MT184.10.08.001
50 2 Piece Valve bridge MT184.10.06.008 X14CrMoS17
51 1 Piece Cylinder cover seal MT184.10.06.009 SBR/B-870M
Item Quantity
Unit Name Item number / Standard
Comments
Tab. 4.1 Spare parts list
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52 2 Piece Flat washer ISO 7089 -8 8-A2
53 2 Piece Hexagon nut ISO 4032-M8 8-A2
54 1 Piece Air chamber seal MT184.10.06.011 SBR/B-870M
55 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
56 2 Piece Stud bolt MT184.10.06.012 X17CrNi16-2
57 2 Piece Stud bolt MT184.10.06.013 X17CrNi16-2
58 2 Piece Seal DIN 7603-A-13x18x1,5
PVC
59 4 Piece Valve seat seal MT184.10.06.014 SBR/B-870M
60 3 Piece Hexagon screw ISO 4017-M6x16 8.8-A2
61 3 Piece Hexagon screw ISO 4017-M8x25 8.8-A2
62 2 Piece Seal MT184.10.06.015 SBR/B-870M
63 1 Piece Plain washer MT184.10.06.016 X17CrNi16-2
64 1 Piece Seal DIN 7603-A-13x18x1,5
PVC
65 1 Piece Seal DIN 7603-A-39x49x2
EPDM
66 1 Piece Valve seat MT184.10.07.001 CuZn40Al2
67 1 Piece Seal in valve seat MT184.10.07.002 80 NBR 180
68 1 Piece Delivery side valve pin MT184.10.01.001 CuZn39Pb3
69 1 Piece Delivery side valve seat Mt184.10.01.002 CuZn39Pb3
70 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
71 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
72 1 Piece Intake side valve pin MT184.10.02.001 CuZn39Pb3
73 1 Piece Intake side valve seat MT184.10.02.002 CuZn39Pb3
74 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
Item Quantity
Unit Name Item number / Standard
Comments
Tab. 4.1 Spare parts list
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75 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
76 1 Piece Hexagon nut ISO 10511.M6 A2
77 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
78 1 Piece Rocker shaft MT184.10.00.001 X14CrMoS17
79 1 Piece Rocker shaft with thread MT184.10.00.002 X14CrMoS17
80 4 Piece Insulating bush MT184.10.00.003 GP-22
81 1 Piece Motor clamp rail left MT184.10.00.004 EN-GJL-200
82 1 Piece Motor clamp rail right MT184.10.00.005 EN-GJL-200
83 1 Piece V-belt pulley MT184.10.00.006 EN-GJL-200
84 1 Piece Hexagon screw ISO 4017-M8x25 8.8
85 5 Piece Hexagon nut ISO 4032-M8 8
86 2 Piece Flat washer ISO 7089-A-8 140 HV
87 3 Piece Hexagon screw ISO 4017-M6x-10 8.8
88 1 Piece Valve housing complete MT184.00.06.000
89 1 Piece Crankcase complete MT184.00.09.000
90 1 Piece Intake valve complete MT184.00.01.000
91 1 Piece Pressure valve complete MT184.00.02.000
92 1 Piece Valve seat MT184.00.07.000
Item Quantity
Unit Name Item number / Standard
Comments
Tab. 4.1 Spare parts list
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5 Assembly and dismantling of the piston pump
5.1 Assembly of the piston pump
The piston pump assembly procedure is divided into eight phases:
• Assembly phase 1 – Crankshaft (assembly unit 1)
• Assembly phase 2 – Connecting rod with piston rod (assembly unit 2)
• Assembly phase 3 – Packing gland (assembly unit 3)
• Assembly phase 4 – Intake valve (assembly unit 4)
• Assembly phase 5 – Pressure valve (assembly unit 5)
• Assembly phase 6 – Gearbox (assembly unit 6)
• Assembly phase 7 – Pump housing (assembly unit 7)
• Assembly phase 8 – Pump
Tools:
• Puller
• Punch
• Wrench size 10 (2 x), size 13, size 14, size 19 and size 22
• Screwdriver
• Vice – not supplied
• Soft hammer
• Jig 1, 2, 3 and 4
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5.1.1 Assembly phase 1 – Crankshaft (assembly unit 1)
Fig. 5.1 Drawing of the crankshaft (assembly unit 1)
Fig. 5.2 Crankshaft, fully assembled (assembly unit 1)
Item Name
3 Crankshaft
24 Grooved ball bearing
25 Grooved ball bearing
3 25 25 24
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Fig. 5.3 Parts required for assembly
Item Name
3 Crankshaft
24 Grooved ball bearing
25 Grooved ball bearing
3 25 25 24
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Procedure for assembling the crankshaft (assembly unit 1)
Grooved ball bearing(item 25)
Grooved ball bearing(item 25)
Grooved ball bearing(item 24)
Crankshaft(item 3)
Crankshaft(assembly unit 1)
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Assembly procedure for crankshaft (assembly unit 1)
• Lightly oil crankshaft (3) to aid assembly of grooved ball bearings.
• Fit grooved ball bearing (25) onto crankshaft (3) and position at connectingrod seat.
• Using a soft hammer and jig 2, drive grooved ball bearing (25) ontocrankshaft, without bending it, until grooved ball bearing contacts recess.
• Fit grooved ball bearing (25) onto drive side of crankshaft (3).
• Using a soft hammer and jig 2, drive grooved ball bearing (25) ontocrankshaft, without bending it, until grooved ball bearing contacts recess.
Fig. 5.4 Assembling the grooved ball bearing with jig 2
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• Using a soft hammer and jig 3, drive grooved ball bearing (24) ontocrankshaft, without bending it, until grooved ball bearing contacts recess.
Fig. 5.5 Assembling the grooved ball bearing with jig 3
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5.1.2 Assembly phase 2 – Connecting rod with piston rod (assembly unit 2)
Fig. 5.6 Drawing of connecting rod with piston rod (assembly unit 2)
Fig. 5.7 Connecting rod with piston rod, fully assembled (assembly unit 2)
Item Name Item Name
1 Connecting rod 29 Hexagon nut
26 Crosshead 30 Hexagon screw
27 Piston Rod 31 Hexagon nut
28 Straight pin
27 29 26 28 1 30, 31
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Fig. 5.8 Parts required for assembly
Item Name Item Name
1 Connecting rod 29 Hexagon nut
26 Crosshead 30 Hexagon screw
27 Piston Rod 31 Hexagon nut
28 Straight pin
29 26 28 31 30
27
1
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Procedure for assembling the connecting rod with piston rod (assembly unit 2)
Crosshead(item 26)
Straight pin(item 28)
Hexagon nut(item 29)
Connecting rod(item 1)
Connecting rod with piston rod
(assembly unit 2)
Piston rod(item 27)
Hexagon screw with hexagon nut
(item 30, 31)
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Assembly procedure for connecting rod with piston rod (assembly unit2)
• Fit crosshead (26) onto connecting rod (1).
• Using a soft hammer and punch, carefully drive straight pin (28) into holein crosshead (26) and connecting rod (1).
• Screw hexagon nut (29) onto thread of piston rod (27).
• Screw piston rod with thread side onto which nut was screwed intocrosshead.
• Tighten hexagon nut against crosshead.
• Screw hexagon screw with hexagon nut (30, 31) into end of connectingrod.
Fig. 5.9 Assembling the crosshead with connecting rod
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5.1.3 Assembly phase 3 – Packing gland (assembly unit 3)
Fig. 5.10 Drawing of the packing gland (assembly unit 3)
Fig. 5.11 Packing gland, fully assembled (assembly unit 3)
Item Name
2 Packing gland housing
32 Packing gland screw
33 Brass washer
34 Gland packing
35 Lip seal
35 32
33 2
34
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Fig. 5.12 Parts required for assembly
32
332, 35
34
Item Name
2 Packing gland housing
32 Packing gland screw
33 Brass washer
34 Gland packing
35 Lip seal
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Procedure for assembling the packing gland (assembly unit 3)
Brass washer(item 33)
Packing gland packing(item 34)
Packing gland housing with lip seal(item 2, 35)
Packing gland(assembly unit 3)
Packing gland screw(item 32)
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Assembly procedure for packing gland (assembly unit 3)
NOTICEThe lip seal (35) is not suitable for repeatedassembly and disassembly, as it would bedamaged. It is pre-assembled.
• Insert brass washer (33) into packing gland housing (2).
• Push four packing gland packs (34) into packing gland housing (2). Theabutment of each must be at a 90° offset.
• Screw packing gland screw (32) into packing gland housing.
Fig. 5.13 Inserting the packing gland packs
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5.1.4 Assembly phase 4 – Intake valve (assembly unit 4)
Fig. 5.14 Drawing of the intake valve (assembly unit 4)
Fig. 5.15 Intake valve, fully assembled (assembly unit 4)
Item Name
72 Intake side valve pin
73 Intake side valve seat
74 Valve rubber plate
75 Hold-down
76 Hexagon nut
72
73
74
75
76
5 Assembly and dismantling of the piston pump 73
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Fig. 5.16 Parts required for assembly
Item Name
72 Intake side valve pin
73 Intake side valve seat
74 Valve rubber plate
75 Hold-down
76 Hexagon nut
76 75
72, 73 74
5 Assembly and dismantling of the piston pump 74
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Procedure for assembling the intake valve (assembly unit 4)
Valve rubber plate(item 74)
Hold-down(item 75)
Intake side valve pin with intake side valve seat
(item 72, 73)
Intake valve(assembly unit 4)
Hexagon screw (item 76)
5 Assembly and dismantling of the piston pump 75
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Assembly procedure for intake valve (assembly unit 4)
NOTICEThe intake side valve pin (72) is pre-assembledwith the intake side valve seat (73).
• Fit valve rubber plate (74) onto intake side valve pin (72) with curved sidefacing outwards.
• Fit hold-down (75) onto valve pin with cylindrical side first.
• Screw hexagon nut (76) onto valve pin.
• Carry out same assembly procedure for second intake valve.
Fig. 5.17 Assembling the hold-down
5 Assembly and dismantling of the piston pump 76
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5.1.5 Assembly phase 5 – Pressure valve (assembly unit 5)
Fig. 5.18 Drawing of the pressure valve (assembly unit 5)
Fig. 5.19 Pressure valve, fully assembled (assembly unit 5)
Item Name
68 Delivery side valve pin
69 Delivery side valve seat
70 Valve rubber plate
71 Hold-down
68
71
70
69
5 Assembly and dismantling of the piston pump 77
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Fig. 5.20 Parts required for assembly
Item Name
68 Delivery side valve pin
69 Delivery side valve seat
70 Valve rubber plate
71 Hold-down
71 68
69 70
5 Assembly and dismantling of the piston pump 78
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Procedure for assembling the pressure valve (assembly unit 5)
Valve rubber plate(item 70)
Hold-down(item 71)
Delivery side valve seat(item 69)
Pressure valve(assembly unit 5)
Delivery side valve pin (item 68)
5 Assembly and dismantling of the piston pump 79
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Assembly procedure for pressure valve (assembly unit 5)
• Place valve rubber plate (70) on ridged side of delivery side valve seat (69)with curved side facing outwards.
• Fit hold-down (71) with cylindrical side first into valve rubber plate (70).
• Fit delivery side valve pin (68) into holes in hold-down and valve seat.Carefully hammer valve pin into valve seat.
• Carry out same assembly procedure for second pressure valve.
Fig. 5.21 Assembling the delivery side valve pin
5 Assembly and dismantling of the piston pump 80
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5.1.6 Assembly phase 6 – Gearbox (assembly unit 6)
Fig. 5.22 Drawing of the gearbox (assembly unit 6)
21, 22
11
6 4, 23
19
A
7 5 B 13 9 12 C 10 17 18
14
5 Assembly and dismantling of the piston pump 81
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Fig. 5.23 Parts list for gearbox (assembly unit 6)
Fig. 5.24 Gearbox, fully assembled (assembly unit 6)
Item Name Item Name
A Crankshaft(assembly unit 1)
11 Bearing cover seal
B Connecting rod with piston rod (assembly unit 2)
12 Oil stripper
C Packing gland(assembly unit 3)
13 Oil plug
4, 23 Bearing cover, open, with radial shaft seal
14 Duo-piston
5 Gearbox housing 17 Hexagon nut
6 Bearing cover, closed 18 Spring ring
7 Gearbox cover 19 Hexagon screw
9 Oil splash guard 21, 22 Angled oiler with nut and seal
10 Packing gland seal
5 Assembly and dismantling of the piston pump 82
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Fig. 5.25 Parts required for assembly
A
B
C
6
7
9
10
11
12
13
14
17, 18
19
21, 22
4, 23
5
Item Name Item Name
A Crankshaft(assembly unit 1)
11 Bearing cover seal
B Connecting rod with piston rod (assembly unit 2)
12 Oil stripper
C Packing gland(assembly unit 3)
13 Oil plug
4, 23 Bearing cover, open, with radial shaft seal
14 Duo-piston
5 Gearbox housing 17 Hexagon nut
6 Bearing cover, closed 18 Spring ring
7 Gearbox cover 19 Hexagon screw
9 Oil splash guard 21, 22 Angled oiler with nut and seal
10 Packing gland seal
5 Assembly and dismantling of the piston pump 83
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Procedure for assembling the gearbox (assembly unit 6)
Oil splash guard(item 9)
Connecting rod with piston rod (assembly
unit 2, item B)
Gearbox housing(item 5)
Oil stripper(item 12)
Packing gland seal(item 10)
Packing gland (assembly unit 3,
item C)
Crankshaft (assembly unit 1,
item A)
5 Assembly and dismantling of the piston pump 84
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Bearing cover seal (item 11)
Hexagon screws (item 19)
Bearing cover seal(item 11)
Bearing cover, closed(item 6)
Hexagon screws(item 19)
Bearing cover seal (item 11)
Bearing cover, open, with radial shaft seal
(item 4, 23)
Hexagon screws (item 19)
Gearbox cover (item 7)
5 Assembly and dismantling of the piston pump 85
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Hexagon nut(item 17)
Duo-piston(item 14)
Gearbox(assembly unit 5)
Spring ring with hexagon nut (item 18, 17)
Angled oiler with seal and nut
(item 21, 22)
Oil plug(item 13)
5 Assembly and dismantling of the piston pump 86
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Assembly procedure for gearbox (assembly unit 6)
• Fit oil splash guard (9) into gearbox housing (5).
• Fit connecting rod with piston rod (B, assembly unit 2) into gearboxhousing (5). Do not yet insert crosshead into guide bush, leaving piston rodprotruding out of oil splash guard slightly.
• Push oil stripper (12) onto piston rod by twisting.
• Place packing gland seal (12) on packing gland (C, assembly unit 3).
• Slot piston rod through packing gland (C, assembly unit 3) and insertcrosshead in guide bush.
• Fit crankshaft (A, assembly unit 1) into connecting rod base. Use ascrewdriver to spread the connecting rod base so the connecting rodbearing can be easily inserted.
Fig. 5.26 Inserting the connecting rod with piston rod
5 Assembly and dismantling of the piston pump 87
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• Place bearing cover seal (11) against gearbox housing.
• Attach closed bearing cover (6) to gearbox housing by hexagon screws(19).
NOTICEThe radial shaft seal (23) is not suitable forrepeated assembly and disassembly, as it wouldbe damaged. It is pre-assembled with the openbearing cover (4).
• Place bearing cover seal (11) against gearbox housing.
• Attach open bearing cover (4) to gearbox housing by hexagon screws (19).
Fig. 5.27 Assembling the crankshaft
5 Assembly and dismantling of the piston pump 88
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• Tighten screw fitting on connecting rod.
• Mount gearbox cover (7) on gearbox housing.
• Screw hexagon nut (17) onto piston rod.
• Fit duo-piston (14) onto piston rod.
• Screw hexagon nut with spring ring (17, 18) against duo-piston (14).
• Screw angled oiler with seal and nut (item 21, 22) onto gearbox housing.
Fig. 5.28 Assembling the open bearing cover
5 Assembly and dismantling of the piston pump 89
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• Insert oil plug (13).
Fig. 5.29 Assembling the angled oiler
5 Assembly and dismantling of the piston pump 90
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5.1.7 Assembly phase 7 – Pump housing (assembly unit 7)
Fig. 5.30 Drawing of the pump housing (assembly unit 7)
42, 5
8
45 63 43 41
4060 59
51
50, 5
2, 5
3
B 59 39
65
47
4861
A
62
46, 7
7
5 Assembly and dismantling of the piston pump 91
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Fig. 5.31 Parts list for gearbox (assembly unit 6)
Fig. 5.32 Pump housing, fully assembled (assembly unit 7)
Item Name Item Name
D Assembly unit 4 49, 64 Poppet valve body with seal
E Assembly unit 4 50 Valve bridge
40 Cylinder cover 51 Cylinder cover seal
41 Air chamber 52 ,53 Hexagon nut with washer
42, 58 Water plug with seal 54 Air chamber seal
43 Air chamber stud bolt 59 Valve seat seal
45, 63 Cap nut with washer 60 Hexagon screws
46, 77 Drain plug with seal 61 Hexagon screws
47, 65 Membrane safety valve with seal 62 Seal
48 Straight flange G1“
5 Assembly and dismantling of the piston pump 92
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Fig. 5.33 Parts required for assembly
Item Name Item Name
D Intake valve (assembly unit 4) 48 Straight flange G1“
E Pressure valve (assembly unit 5) 49, 64 Poppet valve body with seal
39 Pump housing 50 Valve bridge
40 Cylinder cover 51 Cylinder cover seal
41 Air chamber 52, 53 Hexagon nut with washer
42, 58 Water plug with seal 54 Air chamber seal
43 Air chamber stud bolt 59 Valve seat seal
45, 63 Cap nut with washer 60 Hexagon screws
46, 77 Drain plug with seal 61 Hexagon screws
47, 65 Membrane safety valve with seal 62 Seal
D
E
40
41
42, 58
43
45, 63
47, 65
48
49, 64
5051 52, 53
54
59
60
61
62
39
46, 77
5 Assembly and dismantling of the piston pump 93
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Procedure for assembling the pump housing (assembly unit 7)
Valve seat seal(item 59)
Intake valve(assembly unit 4,
item D)
Pump housing(item 39)
Pressure valve(assembly unit 5,
item E)
Valve bridge (item 50)
Hexagon nut with washer(item 32, 53)
Drain plugwith seal
(item 46, 77)
5 Assembly and dismantling of the piston pump 94
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Seal (item 62)
Straight flange(item 48)
Hexagon screws(item 61)
Cylinder cover seal(item 51)
Cylinder cover(item 40)
Hexagon screws(item 60)
Poppet valve body with seal
(item 49, 64)
5 Assembly and dismantling of the piston pump 95
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Air chamber stud bolt (item 43)
Air chamber seal(item 54)
Pump housing(assembly unit 7)
Air chamber(item 41)
Cap nut with washer(item 45, 63)
Water plug with seal(item 42, 58)
Membrane safety valve with seal
(item 47, 65)
5 Assembly and dismantling of the piston pump 96
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Assembly procedure for pump housing (assembly unit 7)
NOTICEThe cylinder pipe is pre-assembled in the pumphousing.
• Place valve seat seal (59) in pump housing (39).
• Place both intake valves (D, assembly unit 4) on one side in pump housing(39).
• Place both pressure valves (E, assembly unit ) on other side in pumphousing.
• Place a valve bridge (50) over each intake valve and pressure valve.
• Screw together valve bridges (50) with hexagon screw and washer (52,53) and already fitted stud bolts.
• Screw drain plug with seal (46, 77) into tapped hole.
Fig. 5.34 Inserting the intake valves and pressure valves in the pump housing
5 Assembly and dismantling of the piston pump 97
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• Fit seals (62) at intake and pressure fittings.
• Screw both straight flanges (48) with hexagon screws (61) to intake andpressure fittings.
• Place cylinder cover seal (51) against pump housing.
• Screw cylinder cover (40) with hexagon screws (60) to pump housing.
• Screw poppet valve body with seal (49, 64) into cylinder cover.
• Screw air chamber bolt (43) into pump housing.
• Push air chamber seal (54) over air chamber bolt and place on housing.
Fig. 5.35 Assembling the cylinder cover
5 Assembly and dismantling of the piston pump 98
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• Fit air chamber (41) onto pump housing. Opening for membrane safetyvalve must be above intake valves.
• Screw cap nut with washer (45, 63) onto air chamber bolt.
• Screw water plug with seal (42, 58) into air chamber.
• Screw membrane safety valve with seal (47, 65) into air chamber using jig1. The valve seat is pre-assembled.
Fig. 5.36 Inserting the air chamber seal
Fig. 5.37 Assembling the membrane safety valve
5 Assembly and dismantling of the piston pump 99
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5.1.8 Assembly phase 8 – Pump
Fig. 5.38 Drawing of the pump (assembly unit 8)
Item Name Item Name
C Packing gland (assembly unit 3) 79 Rocker shaft with thread
F Gearbox (assembly unit 6) 81, 82 Motor clamp rails left and right
G Pump housing (assembly unit 7) 83 V-belt pulley
15 Disk spring 84 Hexagon screw
78 Rocker shaft 85, 86 Hexagon nut with washer
81, 82 79 84, 85 A 87 78 85, 86 C
1583, 87 B
5 Assembly and dismantling of the piston pump 100
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Fig. 5.39 Pump, fully assembled (assembly unit 8)
5 Assembly and dismantling of the piston pump 101
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Fig. 5.40 Parts required for assembly
Item Name Item Name
F Gearbox (assembly unit 6) 81, 82 Motor clamp rails left and right
G Pump housing (assembly unit 7) 83 V-belt pulley
15 Disk spring 84 Hexagon screw
78 Rocker shaft 85, 86 Hexagon nut with washer
79 Rocker shaft with thread 87 Hexagon screw
G
F
157879
81, 82
83, 87
84, 85
87
85, 86
5 Assembly and dismantling of the piston pump 102
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Procedure for assembling the pump (assembly unit 8)
Pump housing (G, assembly unit 7)
Hexagon nut with washer(item 85, 86)
Gearbox (F, assembly unit 6)
Disk spring(item 15)
V-belt pulley with hexagon screw (item 83, 87)
Rocker shaft(item 78)
Motor clamp rails left and right
(item 81, 82)
5 Assembly and dismantling of the piston pump 103
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Hexagon screw (item 87)
Rocker shaft with thread
(item 79)
Piston pump
Hexagon screw with hexagon nut
(item 84, 85)
5 Assembly and dismantling of the piston pump 104
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Assembly procedure for pump (assembly unit 8)
• Grease piston and insert carefully into cylinder pipe.
Then place pump housing (G, assembly unit 7) against Gearbox (F,assembly unit 6).
Screw together pump housing and gearbox with hexagon nut (85) and pre-assembled stud bolts.
• Fit packing gland (C, assembly unit 3) with hexagon nut and washer (85,86) on stud bolts.
• Place disk spring (15) with round side facing downwards into groove incrankshaft.
• Push V-belt pulley (83) with loosely fitted hexagon screw (87) over diskspring onto crankshaft and then tighten hexagon screw.
• Fit rocker shaft (78) into hole on gearbox housing.
Fig. 5.41 Fitted packing gland
5 Assembly and dismantling of the piston pump 105
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• Slot left and right motor clamp rails (81, 82) with pre-assembled hexagonscrew side onto rocker shaft. The insulating bushes are pre-assembled inthe motor clamp rails.
• Fix rocker shaft with hexagon screw (87) on gearbox housing.
• Route rocker shaft with thread (79) into rear holes on motor clamp rails.
• Screw hexagon screw (84) into tapped hole of rocker shaft with thread (79)and lock with hexagon nut (85).
Fig. 5.42 Gearbox housing with rocker shafts and V-belt pulley
Fig. 5.43 Assembling the rocker shaft
5 Assembly and dismantling of the piston pump 106
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5.2 Dismantling the piston pump
5.2.1 Dismantling assembly phase 8 – Pump
• Loosen hexagon nut (85) and unscrew hexagon screw (84) from tappedhole of rocker shaft with thread (79).
• Pull rocker shaft with thread (79) out of rear holes on motor clamp rails.
• Detach left and right motor clamp rails (81, 82) from rocker shaft. Theinsulating bushes remain fitted in the motor clamp rails.
• Unscrew hexagon screw (87) from gearbox housing
• Pull rocker shaft (78) out of hole in gearbox housing.
• Loosen hexagon screw (87) and detach V-belt pulley (83) from crankshaftover disk spring.
Fig. 5.44 Dismantling the rocker shaft
5 Assembly and dismantling of the piston pump 107
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• Lever disk spring (15) out of groove on crankshaft with screwdriver.
• Unscrew hexagon nut and washer (85, 86) from stud bolts and detachpacking gland (C, assembly unit 3) from pump.
• Unscrew hexagon nut (85) from stud bolts and detach pump housing (G,assembly unit 7) from gearbox (F, assembly unit 6). Carefully guide pistonout of cylinder pipe when doing so.
Fig. 5.45 Dismantling the V-belt pulley
Fig. 5.46 Dismantling the pump housing
5 Assembly and dismantling of the piston pump 108
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Fig. 5.47 Piston pumps, dismantled into assembly units
5 Assembly and dismantling of the piston pump 109
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5.2.2 Dismantling assembly phase 7 – Pump housing
• Unscrew membrane safety valve (47) from air chamber (41) using jig 1.Remove seal (65).
NOTICEThe valve seat of the membrane safety valveremains fitted.
• Unscrew water plug with seal (42, 58) from air chamber (41).
• Unscrew cap nut with washer (45, 63) from air chamber bolt (43).
• Lift air chamber (41) from pump housing (39).
• Pull air chamber seal (54) over air chamber bolt (43) and remove fromhousing.
• Unscrew air chamber bolt from pump housing (39).
• Unscrew poppet valve body with seal (49, 64) from cylinder cover (40).
Fig. 5.48 Removing the air chamber
5 Assembly and dismantling of the piston pump 110
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• Loosen hexagon screws (60) and take cylinder cover (40) with cylindercover seal (51) from pump housing.
• Loosen hexagon screws (61) and remove both straight flanges (48) withseals (62) from intake and pressure fittings.
• Unscrew drain plug with seal (46, 77) from tapped hole in pump housing.
• Unscrew hexagon screws and washers (52, 53) from stud bolts on valvebridges (50).
• Lift valve bridges (50) from intake and pressure valves.
Fig. 5.49 Dismantling the poppet valve body
Fig. 5.50 Removing the intake and pressure valves
5 Assembly and dismantling of the piston pump 111
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• Take pressure valve (E, assembly unit 5) out of pump housing.
• Take intake valve (D, assembly unit 4) out of pump housing.
• Remove valve seat seal (59) from pump housing.
NOTICEThe cylinder pipe remains fitted in the pumphousing.
Fig. 5.51 Pump housing, dismantled
5 Assembly and dismantling of the piston pump 112
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5.2.3 Dismantling assembly phase 6 – Gearbox
• Remove oil plug (13).
• Unscrew angled oiler with seal and nut (item 21, 22) from gearbox housing(5).
• Unscrew hexagon nut with spring ring (17, 18) from duo-piston (14).
• Pull duo-piston (14) from piston rod (27).
• Unscrew hexagon nut (17) from piston rod (27).
• Lever gearbox cover (7) from gearbox housing (5).
• Unscrew hexagon screws (19) from gearbox housing and remove openbearing cover (4) with bearing cover seal (11) from gearbox housing.
NOTICEThe radial shaft seal (23) is not suitable forrepeated assembly and disassembly, as it wouldbe damaged. It remains fitted in the open bearingcover (4).
• Unscrew hexagon screws (19) from gearbox housing and remove closedbearing cover (6) with bearing cover seal (11) from gearbox housing.
Fig. 5.52 Detaching the duo-piston
5 Assembly and dismantling of the piston pump 113
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• Loosen screw fitting on connecting rod.
• Pull crankshaft (A, assembly unit 1) out of connecting rod base. Use ascrewdriver to spread the connecting rod base so the connecting rodbearing can be easily removed.
• Pull piston rod out of packing gland (C, assembly unit 3) and crossheadout of guide bush. Leave connecting rod in gearbox housing.
Fig. 5.53 Loosening the connecting rod screw fitting
Fig. 5.54 Removing the packing gland
5 Assembly and dismantling of the piston pump 114
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• Take packing gland seal (12) from packing gland (C, assembly unit 3).
• Pull oil stripper (12) from piston rod by twisting.
• Take connecting rod with piston rod (B, assembly unit 2) out of gearboxhousing (5).
• Lever oil splash guard (9) from gearbox housing (5).
Fig. 5.55 Gearbox, dismantled
5 Assembly and dismantling of the piston pump 115
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5.2.4 Dismantling assembly phase 5 – Pressure valve
• Carefully hammer delivery side valve pin (68) out of delivery side valveseat (69).
• Pull valve pin out of hole in hold-down (71) and valve seat.
• Pull hold-down (71) out of valve rubber plate (70).
• Take valve rubber plate (70) from valve seat.
• Carry out same dismantling procedure for second pressure valve.
Fig. 5.56 Driving valve pin out of valve seat
Fig. 5.57 Pressure valve, disassembled
5 Assembly and dismantling of the piston pump 116
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5.2.5 Dismantling assembly phase 4 – Intake valve
• Unscrew hexagon nut (76) from intake side valve pin (72).
• Pull hold-down (75) from intake side valve pin (73).
• Take valve rubber plate (74) from intake side valve pin (72).
• Intake side valve pin (72) remains assembled with intake side valve seat(73).
• Carry out same dismantling procedure for second intake valve.
Fig. 5.58 Removing the valve rubber plate
Fig. 5.59 Pressure valve, disassembled
5 Assembly and dismantling of the piston pump 117
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5.2.6 Dismantling assembly phase 3 – Packing gland
• Unscrew packing gland screw (32) from packing gland housing (2).
• Drive packing gland packs (34) out of packing gland housing (2). Strike thebrass washer (33) with a punch to do so.
• Take brass washer (33) out of packing gland housing.
NOTICEThe lip seal (35) is not suitable for repeatedassembly and disassembly, as it would bedamaged. It remains fitted.
Fig. 5.60 Driving out the packing gland packs
Fig. 5.61 Packing gland, disassembled
5 Assembly and dismantling of the piston pump 118
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5.2.7 Dismantling assembly phase 2 – Connecting rod with piston rod
• Unscrew hexagon screw with hexagon nut (30, 31) from end of connectingrod.
• Loosen hexagon nut (29) of crosshead and unscrew piston rod (27) fromcrosshead (26).
• Unscrew hexagon nut (29) from thread of piston rod (27).
• Using a soft hammer and punch, carefully drive straight pin (28) out of holein crosshead (26) and connecting rod (1).
• Take crosshead (26) from connecting rod (1).
Fig. 5.62 Driving out the straight pin
Fig. 5.63 Connecting rod, dismantled
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5.2.8 Dismantling assembly phase 1 – Crankshaft
• Place puller over grooved ball bearing (24).
Press hook arms evenly onto grooved ball bearing.
Turn adjuster thread against shaft end. Ensure jig is centred.
Detach grooved ball bearing from crankshaft (3) by carefully turningadjuster thread.
• Pull grooved ball bearing (25) from crankshaft in same way using a puller.
• Place grooved ball bearing (25) with crankshaft on jig 4.
Drive the grooved ball bearing from the shaft by carefully hammering onthe shaft. Use jig 4 and an additional vice as braces.
Fig. 5.64 Pulling off the grooved ball bearing
5 Assembly and dismantling of the piston pump 120
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Fig. 5.65 Driving out the grooved ball bearing
Fig. 5.66 Crankshaft, dismantled
5 Assembly and dismantling of the piston pump 121
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6 Tasks
Tasks / Exercises Topic
Worksheet 1 Introduction to the piston pump
Worksheet 2 Design, function and applications
Worksheet 3 Identifying causes of faults
Worksheet 4 Sealing systems
Worksheet 5 Inspection
Worksheet 6 Servicing
Worksheet 7 Repairs
Worksheet 8 Wearing parts
Worksheet 9 Assembly of the piston pump
Worksheet 10 Piston replacement
Worksheet 11 Parts identification using the spare parts drawing
Worksheet 12 Spare parts ordering
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6.1 Spare parts drawing and spare parts list
Fig. 6.1 Spare parts drawing for the piston pump
83, 8
7
81, 8
2
79, 8
084
, 85
8779
, 80
85, 8
6
8
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Fig. 6.2 Spare parts drawings for the gearbox
19
6
22
21
4, 23
16
11
3 - 15
8
20
10
3435 14
171833
2
321227913 29282657 1 30,31 24 25
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Fig. 6.3 Spare parts drawings for the pump housing
4245 63 43
4060
51
50, 5
2, 5
3
59
39
65
47
4861
7462
46, 7
776757372
4767
6658
41
54 68
69
7071
4457
58
3849
373664
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Item Quantity
Unit Name Item number / Standard
Comments
1 1 Piece Connecting rod MT184.10.04.001
2 1 Piece Packing gland housing MT184.10.05.002
3 1 Piece Crankshaft MT184.10.03.001
4 1 Piece Bearing cover, open MT184.10.10.001
5 1 Piece Gearbox housing MT184.10.09.001 EN-GJL-200
6 1 Piece Bearing cover, closed MT184.10.09.002 EN-GJL-200
7 1 Piece Gearbox cover MT184.10.09.003 DOC04
8 1 Piece Base plate MT184.10.09.004 S235JR
9 1 Piece Oil splash guard MT184.10.09.005 DOC04
10 1 Piece Packing gland seal MT184.10.09.006 SBR/B-870M
11 2 Piece Bearing cover seal MT184.10.09.007 SBR/B-870M
12 1 Piece Oil stripper MT184.10.09.008 60NBR693 SW
13 1 Piece Oil plug MT184.10.09.009 CuZn39Pb3
14 1 Piece Duo-piston PM10 Simirit
15 1 Piece Disk spring DIN 6888-5x7,5
16 8 Piece Hexagon nut ISO 4032-M6 8
17 2 Piece Hexagon nut ISO 4032-M8 8
18 1 Piece Spring ring DIN 127-A-8 A2
19 6 Piece Hexagon screw ISO 4017-M6x12 8.8
20 4 Piece Rubber buffer 500029 GMT
21 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
22 2 Piece Angled oiler with nut G1/8 Spike
23 1 Piece Radial shaft seal DIN 3760-A-16x35x7
NBR
24 2 Piece Grooved ball bearing DIN 625-6202
25 1 Piece Grooved ball bearing DIN 625-6203
Tab. 6.1 Spare parts list
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26 1 Piece Crosshead MT184.10.04.002 EN-GJL-200
27 1 Piece Piston Rod MT184.10.04.003 X14CrMoS17
28 1 Piece Straight pin ISO 8734-12x35 C1
29 1 Piece Hexagon nut ISO 4032-M8 8-A2
30 1 Piece Hexagon screw ISO 4017-M6x25 8.8
31 1 Piece Hexagon nut ISO 4032-M6 8-A2
32 1 Piece Packing gland screws MT184.10.05.002 CuZn39Pb3
33 1 Piece Brass washer MT184.10.05.003 CuZn37F30
34 1 Piece Gland packing 00.2251 Spike
35 1 Piece Lip seal ISO 4032-M8 A2-70
36 1 Piece Lock nut MT184.10.09.002 CuZn39Pb2
37 1 Piece Knurled screw MT184.10.08.003 CuZn39Pb3
38 1 Piece Cap MT184.10.08.004 NBR
39 1 Piece Pump housing MT184.10.06.001 EN-GJL-200
40 1 Piece Cylinder cover MT184.10.06.002 EN-GJL-200
41 1 Piece Air chamber MT184.10.06.003 EN-GJL-200
42 1 Piece Water plug MT184.10.06.004 CuZn39Pb2
43 1 Piece Air chamber stud bolt MT184.10.06.005 9SMn28K
44 1 Piece Cylinder pipe MT184.10.06.006 X6CrNi18-10
45 1 Piece Cap nut DIN 1587-M12 CuZn39Pb3
46 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
47 1 Piece Membrane safety valve SV.01-065.7,5 F3000.4
Spike
48 2 Piece Straight flange G1“ MT184.10.06.010 EN-GJL-200
49 1 Piece Poppet valve body MT184.10.08.001
50 2 Piece Valve bridge MT184.10.06.008 X14CrMoS17
51 1 Piece Cylinder cover seal MT184.10.06.009 SBR/B-870M
Item Quantity
Unit Name Item number / Standard
Comments
Tab. 6.1 Spare parts list
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52 2 Piece Flat washer ISO 7089 -8 8-A2
53 2 Piece Hexagon nut ISO 4032-M8 8-A2
54 1 Piece Air chamber seal MT184.10.06.011 SBR/B-870M
55 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
56 2 Piece Stud bolt MT184.10.06.012 X17CrNi16-2
57 2 Piece Stud bolt MT184.10.06.013 X17CrNi16-2
58 2 Piece Seal DIN 7603-A-13x18x1,5
PVC
59 4 Piece Valve seat seal MT184.10.06.014 SBR/B-870M
60 3 Piece Hexagon screw ISO 4017-M6x16 8.8-A2
61 3 Piece Hexagon screw ISO 4017-M8x25 8.8-A2
62 2 Piece Seal MT184.10.06.015 SBR/B-870M
63 1 Piece Plain washer MT184.10.06.016 X17CrNi16-2
64 1 Piece Seal DIN 7603-A-13x18x1,5
PVC
65 1 Piece Seal DIN 7603-A-39x49x2
EPDM
66 1 Piece Valve seat MT184.10.07.001 CuZn40Al2
67 1 Piece Seal in valve seat MT184.10.07.002 80 NBR 180
68 1 Piece Delivery side valve pin MT184.10.01.001 CuZn39Pb3
69 1 Piece Delivery side valve seat Mt184.10.01.002 CuZn39Pb3
70 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
71 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
72 1 Piece Intake side valve pin MT184.10.02.001 CuZn39Pb3
73 1 Piece Intake side valve seat MT184.10.02.002 CuZn39Pb3
74 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
Item Quantity
Unit Name Item number / Standard
Comments
Tab. 6.1 Spare parts list
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75 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
76 1 Piece Hexagon nut ISO 10511.M6 A2
77 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
78 1 Piece Rocker shaft MT184.10.00.001 X14CrMoS17
79 1 Piece Rocker shaft with thread MT184.10.00.002 X14CrMoS17
80 4 Piece Insulating bush MT184.10.00.003 GP-22
81 1 Piece Motor clamp rail left MT184.10.00.004 EN-GJL-200
82 1 Piece Motor clamp rail right MT184.10.00.005 EN-GJL-200
83 1 Piece V-belt pulley MT184.10.00.006 EN-GJL-200
84 1 Piece Hexagon screw ISO 4017-M8x25 8.8
85 5 Piece Hexagon nut ISO 4032-M8 8
86 2 Piece Flat washer ISO 7089-A-8 140 HV
87 3 Piece Hexagon screw ISO 4017-M6x-10 8.8
88 1 Piece Valve housing complete MT184.00.06.000
89 1 Piece Crankcase complete MT184.00.09.000
90 1 Piece Intake valve complete MT184.00.01.000
91 1 Piece Pressure valve complete MT184.00.02.000
92 1 Piece Valve seat MT184.00.07.000
Item Quantity
Unit Name Item number / Standard
Comments
Tab. 6.1 Spare parts list
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6.2 Worksheet 1: Introduction to the piston pump, page 1
Objective:
To obtain an overview of the design and function of the piston pump.
Exercise:
You are provided with an assembled pump. Dismantle the pump so that allthe component parts are laid out before you.
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Worksheet 1, page 2
Pick up the pump drawings and the parts list. Locate the components in thedrawings. Refer to the parts list to find out the correct names of thecomponents.
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Worksheet 1, page 3
You are now familiar enough with the overall design of the pump to be ableto answer the following questions:
1. With what type of displacement device is the pump fitted?
2. Does a piston pump have a specific direction of rotation? Or are clockwiseand anti-clockwise both possible?
3. Can you explain the basic operating principle of a piston pump?
4. Look at the materials in the parts list. For which media could the pump besuitable?
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6.3 Worksheet 2: Design, function and applications of the piston pump, page 1
Objective:
To explain the design of the pump. To understand and describe its method ofoperation and usage.
Exercise:
1. Describe the design of the pump.
Use the drawings.
2. Name the five key components.
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Worksheet 2, page 2
3. Explain the method of operation of the pump. Explain the deliveryprinciple.
4. In what areas is the piston pump used?
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6.4 Worksheet 3: Identifying causes of faults, page 1
Objective:
To identify or suspect likely causes of faults in response to specificmalfunctions while the pump is operating.
Exercise:
Try to find the causes of the faults listed in the table below. Note down yourassumptions in the right-hand section of the table. You can exclude system-related disturbances.
Fault Suspected cause
Medium leaking from pump body
Running noise has markedly increased
The pressure difference usually generated between the inlet and outlet is no longer being attained
The pressure difference is much less than normal
The pump housing has a much higher surface temperature than normal
The current consumption of the drive motor has increased significantly compared to normal operating conditions
Service life of piston too short
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6.5 Worksheet 4: Sealing systems, page 1
Objective:
To divide sealing systems into basic categories and identify them based onthe example of the pistons.
Information: Sealing systems we can find in pumps are classified as follows:
Static seals
(seals subject to stationary stress)
Dynamic seals
(seals subject to motion)
Sealing systems
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Worksheet 4, page 2
Exercise:
1. Here you see the sectional drawing of the pump.
• In the sectional drawing, mark the static seals as S and the dynamicseals as D.
• What functions do the static and dynamic seals perform?
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Worksheet 4, page 3
When you have identified the sealing systems used in the piston pump, moveon to the following exercise.
2. Describe the design and method of operation of a shaft seal based on thefloating ring principle.
3. Look at a shaft seal based on the packing gland principle and describe it.
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6.6 Worksheet 5: Inspection of pumps, page 1
Objective:
To know what the term “inspection” involves, and to draw up an inspectionplan.
Exercise:
1. What does the term “inspection” mean in the context of technicalmaintenance?
Mark the statements you consider to be true or false in the Yes or Nocolumn of the following table as appropriate.
Activity Yes No
The current actual status of a pump is recorded and assessed
Components such as pistons or seals are replaced as a preventive maintenance measure
Shaft bearings are lubricated and couplings re-aligned
Entire pump units are replaced
An inspection is always carried out with the system stopped
During an inspection operating data of the pump system are measured (read) and entered in an inspection plan
An inspection can be seen as equivalent to preventive repair
Inspection is a routine operation in machinery and plant maintenance
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Worksheet 5, page 2
When you have established what the term “inspection” means, move on tothe following exercise.
2. Imagine we were talking about a vital piston pump in a domestic waterprocess. Let’s also assume that this pump is similar in design to the pumpfrom our MT 184 practice kit.
Draw up an inspection plan by mean of which an inspection can bedocumented.
Inspection plan
Pump: Inspected by:
Serial no.: Date:
Item Comments
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6.7 Worksheet 6: Servicing of pumps, page 1
Objective:
To know what is meant by the term “servicing”.
Exercise:
1. What does the term “servicing” mean in the context of technicalmaintenance?
Mark the statements you consider to be true or false in the Yes or Nocolumn of the following table as appropriate.
Activity Yes No
Components such as pistons, rod seals and gaskets are replaced as a preventive maintenance measure
The object of servicing is to record and assess the current actual status of a pump
Servicing of a pump is a routine operation, carried out at predetermined intervals
A service is usually carried out with the system stopped
Servicing can be seen as equivalent to preventive repair
During a service, packing glands are repositioned, couplings adjusted or oil fillings changed for example
Entire pump units are replaced
Servicing is always carried out when damage to a pump is identified
6 Tasks 141
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Worksheet 6, page 2
When you have established what the term “servicing” means, move on to thefollowing exercise.
2. Do you think that routine servicing is useful and necessary for the pistonpump from our MT 184 practice kit?
Give reasons for your decision.
3. Let’s assume that two piston pumps with the classic differing shaft sealsare being used in a domestic water process.
What servicing operations need to be carried out on the packing gland typeshaft seal and on the floating ring seal type?
6 Tasks 142
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6.8 Worksheet 7: Repairs to pumps, page 1
Objective:
To know what is meant by the term “repairs” in this context and to draw up apreventive maintenance plan.
Exercise:
1. What does the term “repairs” mean in the context of technicalmaintenance?
Mark the statements you consider to be true or false in the Yes or Nocolumn of the following table as appropriate.
Activity Yes No
Repairs involve replacing well-used parts with new ones, for example pistons and seals
Repairs are carried out when damage has occurred to the pump
Repairs may also be carried out as routine and preventive maintenance measures to prevent damage and stoppages from occurring in the first place
Entire pump units are replaced
Preventive maintenance can prevent a pump from failing
Repairs are normally carried out with the system stopped
If servicing is carried out on a regular basis, repairs are not needed
6 Tasks 143
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Worksheet 7, page 2
When you have established what the term “repairs” means, move on to thefollowing exercise.
2. Let us assume that our piston pump represents an important assembly ina domestic water process. A failure of the pump would result in the entireline being shut down.
In view of this, the pump is inspected and serviced at regular intervals.
To achieve the most reliable operation possible, the plant managementdecides to carry out routine preventive repairs to the unit.
Draw up a repair order for carrying out and documenting the work.
Use the drawings.
Inspection order
Pump: Inspected by:
Serial no.: Date:
Procedure Comments/Status
Parts to be replaced:
Parts to be checked:
6 Tasks 144
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6.9 Worksheet 8: Wearing parts on the piston pump, page 1
Objective:
To identify the wearing parts on the piston pump.
Exercise:
1. Mark the wearing parts on the pump drawing and name them by way ofexample.
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Worksheet 8, page 2
2. Of what material are the wearing parts of the piston pump made?
Enter the wearing parts from the previous page in the table with theirmaterial data or standard designations.
Wearing part Material
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6.10 Worksheet 9: Assembling the piston pump, page 1
Objective:
To structure the assembly process. To identify which assembly units andphases can be compiled.
Exercise:
You have laid out all the component parts of the piston pump in front of you.Your task is to assemble the pump.
To do this, first assembly individual assembly units. Then combine theassembly units to create the overall system in a sequence of assemblyphases.
1. Collect the components from which you can compile assembly units andphases. Name the assembly units and phases.
Use the drawings.
•
Item Name
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Worksheet 9, page 2
•
•
•
Item Name
Item Name
Item Name
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Worksheet 9, page 3
•
•
Item Name
Item Name
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Worksheet 9, page 4
•
Item Name
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Worksheet 9, page 5
2. When you have put together the various assembly units, the next step isto assemble the pump.
You should carry out this phase and represent it in a structurecorresponding to the pattern shown.
Set out the identified assembly phases through to the complete pump.
Parts x, y, ...
Parts x, y, ...
Gearing
Piston pump
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Worksheet 9, page 6
Procedure for assembling the piston pump
Gearbox(assembly unit 6)
Piston pump
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6.11 Worksheet 10: Piston replacement, page 1
Objective:
Planning and execution of piston replacement on a piston pump.
Exercise:
1. Your task is to replace the piston on a piston pump.
Set out your method in the pre-compiled work plan. Use the drawings.
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Worksheet 10, page 2
Work plan
Name: Piston pump – Piston replacement
Date: Carried out by:
Order no.: Date:
Procedure
Procedure Tools
Dismantling
Assembly
Estimated time required: ____ min
6 Tasks 154
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6.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1
Objective:
To assign items from a spare parts list to a spare parts drawing.
Exercise:
You are given a spare parts drawing on which the item numbers have not yetbeen entered. Refer to the supplied spare parts list.
Enter the item numbers from the 1st column of the spare parts list in the fieldsin the spare parts drawing.
6 Tasks 155
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Worksheet 11, page 2
Fig. 6.4 Spare parts drawing for the piston pump
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Worksheet 11, page 3
Fig. 6.5 Spare parts drawings for the gearbox
6 Tasks 157
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Worksheet 11, page 4
Fig. 6.6 Spare parts drawings for the pump housing
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Worksheet 11, page 5
Item Quantity
Unit Name Item number / Standard
Comments
1 1 Piece Connecting rod MT184.10.04.001
2 1 Piece Packing gland housing MT184.10.05.002
3 1 Piece Crankshaft MT184.10.03.001
4 1 Piece Bearing cover, open MT184.10.10.001
5 1 Piece Gearbox housing MT184.10.09.001 EN-GJL-200
6 1 Piece Bearing cover, closed MT184.10.09.002 EN-GJL-200
7 1 Piece Gearbox cover MT184.10.09.003 DOC04
8 1 Piece Base plate MT184.10.09.004 S235JR
9 1 Piece Oil splash guard MT184.10.09.005 DOC04
10 1 Piece Packing gland seal MT184.10.09.006 SBR/B-870M
11 2 Piece Bearing cover seal MT184.10.09.007 SBR/B-870M
12 1 Piece Oil stripper MT184.10.09.008 60NBR693 SW
13 1 Piece Oil plug MT184.10.09.009 CuZn39Pb3
14 1 Piece Duo-piston PM10 Simirit
15 1 Piece Disk spring DIN 6888-5x7,5
16 8 Piece Hexagon nut ISO 4032-M6 8
17 2 Piece Hexagon nut ISO 4032-M8 8
18 1 Piece Spring ring DIN 127-A-8 A2
19 6 Piece Hexagon screw ISO 4017-M6x12 8.8
20 4 Piece Rubber buffer 500029 GMT
21 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
22 2 Piece Angled oiler with nut G1/8 Spike
23 1 Piece Radial shaft seal DIN 3760-A-16x35x7
NBR
24 2 Piece Grooved ball bearing DIN 625-6202
25 1 Piece Grooved ball bearing DIN 625-6203
Tab. 6.2 Spare parts list
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Worksheet 11, page 6
Item Quantity
Unit Name Item number / Standard
Comments
26 1 Piece Crosshead MT184.10.04.002 EN-GJL-200
27 1 Piece Piston Rod MT184.10.04.003 X14CrMoS17
28 1 Piece Straight pin ISO 8734-12x35 C1
29 1 Piece Hexagon nut ISO 4032-M8 8-A2
30 1 Piece Hexagon screw ISO 4017-M6x25 8.8
31 1 Piece Hexagon nut ISO 4032-M6 8-A2
32 1 Piece Packing gland screws MT184.10.05.002 CuZn39Pb3
33 1 Piece Brass washer MT184.10.05.003 CuZn37F30
34 1 Piece Gland packing 00.2251 Spike
35 1 Piece Lip seal ISO 4032-M8 A2-70
36 1 Piece Lock nut MT184.10.09.002 CuZn39Pb2
37 1 Piece Knurled screw MT184.10.08.003 CuZn39Pb3
38 1 Piece Cap MT184.10.08.004 NBR
39 1 Piece Pump housing MT184.10.06.001 EN-GJL-200
40 1 Piece Cylinder cover MT184.10.06.002 EN-GJL-200
41 1 Piece Air chamber MT184.10.06.003 EN-GJL-200
42 1 Piece Water plug MT184.10.06.004 CuZn39Pb2
43 1 Piece Air chamber stud bolt MT184.10.06.005 9SMn28K
44 1 Piece Cylinder pipe MT184.10.06.006 X6CrNi18-10
45 1 Piece Cap nut DIN 1587-M12 CuZn39Pb3
46 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
47 1 Piece Membrane safety valve SV.01-065.7,5 F3000.4
Spike
48 2 Piece Straight flange G1“ MT184.10.06.010 EN-GJL-200
49 1 Piece Poppet valve body MT184.10.08.001
50 2 Piece Valve bridge MT184.10.06.008 X14CrMoS17
Tab. 6.3 Spare parts list
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Worksheet 11, page 7
Item Quantity
Unit Name Item number / Standard
Comments
51 1 Piece Cylinder cover seal MT184.10.06.009 SBR/B-870M
52 2 Piece Flat washer ISO 7089 -8 8-A2
53 2 Piece Hexagon nut ISO 4032-M8 8-A2
54 1 Piece Air chamber seal MT184.10.06.011 SBR/B-870M
55 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
56 2 Piece Stud bolt MT184.10.06.012 X17CrNi16-2
57 2 Piece Stud bolt MT184.10.06.013 X17CrNi16-2
58 2 Piece Seal DIN 7603-A-13x18x1,5
PVC
59 4 Piece Valve seat seal MT184.10.06.014 SBR/B-870M
60 3 Piece Hexagon screw ISO 4017-M6x16 8.8-A2
61 3 Piece Hexagon screw ISO 4017-M8x25 8.8-A2
62 2 Piece Seal MT184.10.06.015 SBR/B-870M
63 1 Piece Plain washer MT184.10.06.016 X17CrNi16-2
64 1 Piece Seal DIN 7603-A-13x18x1,5
PVC
65 1 Piece Seal DIN 7603-A-39x49x2
EPDM
66 1 Piece Valve seat MT184.10.07.001 CuZn40Al2
67 1 Piece Seal in valve seat MT184.10.07.002 80 NBR 180
68 1 Piece Delivery side valve pin MT184.10.01.001 CuZn39Pb3
69 1 Piece Delivery side valve seat Mt184.10.01.002 CuZn39Pb3
70 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
71 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
72 1 Piece Intake side valve pin MT184.10.02.001 CuZn39Pb3
73 1 Piece Intake side valve seat MT184.10.02.002 CuZn39Pb3
Tab. 6.4 Spare parts list
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Worksheet 11, page 8
Item Quantity
Unit Name Item number / Standard
Comments
74 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
75 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
76 1 Piece Hexagon nut ISO 10511.M6 A2
77 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
78 1 Piece Rocker shaft MT184.10.00.001 X14CrMoS17
79 1 Piece Rocker shaft with thread MT184.10.00.002 X14CrMoS17
80 4 Piece Insulating bush MT184.10.00.003 GP-22
81 1 Piece Motor clamp rail left MT184.10.00.004 EN-GJL-200
82 1 Piece Motor clamp rail right MT184.10.00.005 EN-GJL-200
83 1 Piece V-belt pulley MT184.10.00.006 EN-GJL-200
84 1 Piece Hexagon screw ISO 4017-M8x25 8.8
85 5 Piece Hexagon nut ISO 4032-M8 8
86 2 Piece Flat washer ISO 7089-A-8 140 HV
87 3 Piece Hexagon screw ISO 4017-M6x-10 8.8
88 1 Piece Valve housing complete MT184.00.06.000
89 1 Piece Crankcase complete MT184.00.09.000
90 1 Piece Intake valve complete MT184.00.01.000
91 1 Piece Pressure valve complete MT184.00.02.000
92 1 Piece Valve seat MT184.00.07.000
Tab. 6.5 Spare parts list
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6.13 Worksheet 12: Spare parts ordering, page 1
Objective:
To place a technically unambiguous spare parts order.
Exercise:
You are going to carry out a repair, and need replacement parts for yourpiston pump.
Select three parts and make a spare parts order.
Use the documents provided.
Spare parts order for pump:
Parts:
6 Tasks 163
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7 Solutions
Tasks / Exercises Topic
Worksheet 1 Introduction to the piston pump
Worksheet 2 Design, function and applications
Worksheet 3 Identifying causes of faults
Worksheet 4 Sealing systems
Worksheet 5 Inspection
Worksheet 6 Servicing
Worksheet 7 Repairs
Worksheet 8 Wearing parts
Worksheet 9 Assembly of the piston pump
Worksheet 10 Piston replacement
Worksheet 11 Parts identification using the spare parts drawing
Worksheet 12 Spare parts ordering
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7.1 Spare parts drawing and spare parts list
Fig. 7.1 Spare parts drawing for the piston pump
83, 8
7
81, 8
2
79, 8
084
, 85
8779
, 80
85, 8
6
8
7 Solutions 165
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Fig. 7.2 Spare parts drawings for the gearbox
19
6
22
21
4, 23
16
11
3 - 15
8
20
10
3435 14
171833
2
321227913 29282657 1 30,31 24 25
7 Solutions 166
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Fig. 7.3 Spare parts drawings for the pump housing
4245 63 43
4060
51
50, 5
2, 5
3
59
39
65
47
4861
7462
46, 7
776757372
4767
6658
41
54 68
69
7071
4457
58
3849
373664
7 Solutions 167
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Item Quantity
Unit Name Item number / Standard
Comments
1 1 Piece Connecting rod MT184.10.04.001
2 1 Piece Packing gland housing MT184.10.05.002
3 1 Piece Crankshaft MT184.10.03.001
4 1 Piece Bearing cover, open MT184.10.10.001
5 1 Piece Gearbox housing MT184.10.09.001 EN-GJL-200
6 1 Piece Bearing cover, closed MT184.10.09.002 EN-GJL-200
7 1 Piece Gearbox cover MT184.10.09.003 DOC04
8 1 Piece Base plate MT184.10.09.004 S235JR
9 1 Piece Oil splash guard MT184.10.09.005 DOC04
10 1 Piece Packing gland seal MT184.10.09.006 SBR/B-870M
11 2 Piece Bearing cover seal MT184.10.09.007 SBR/B-870M
12 1 Piece Oil stripper MT184.10.09.008 60NBR693 SW
13 1 Piece Oil plug MT184.10.09.009 CuZn39Pb3
14 1 Piece Duo-piston PM10 Simirit
15 1 Piece Disk spring DIN 6888-5x7,5
16 8 Piece Hexagon nut ISO 4032-M6 8
17 2 Piece Hexagon nut ISO 4032-M8 8
18 1 Piece Spring ring DIN 127-A-8 A2
19 6 Piece Hexagon screw ISO 4017-M6x12 8.8
20 4 Piece Rubber buffer 500029 GMT
21 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
22 2 Piece Angled oiler with nut G1/8 Spike
23 1 Piece Radial shaft seal DIN 3760-A-16x35x7
NBR
24 2 Piece Grooved ball bearing DIN 625-6202
25 1 Piece Grooved ball bearing DIN 625-6203
Tab. 7.1 Spare parts list
7 Solutions 168
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26 1 Piece Crosshead MT184.10.04.002 EN-GJL-200
27 1 Piece Piston Rod MT184.10.04.003 X14CrMoS17
28 1 Piece Straight pin ISO 8734-12x35 C1
29 1 Piece Hexagon nut ISO 4032-M8 8-A2
30 1 Piece Hexagon screw ISO 4017-M6x25 8.8
31 1 Piece Hexagon nut ISO 4032-M6 8-A2
32 1 Piece Packing gland screws MT184.10.05.002 CuZn39Pb3
33 1 Piece Brass washer MT184.10.05.003 CuZn37F30
34 1 Piece Gland packing 00.2251 Spike
35 1 Piece Lip seal ISO 4032-M8 A2-70
36 1 Piece Lock nut MT184.10.09.002 CuZn39Pb2
37 1 Piece Knurled screw MT184.10.08.003 CuZn39Pb3
38 1 Piece Cap MT184.10.08.004 NBR
39 1 Piece Pump housing MT184.10.06.001 EN-GJL-200
40 1 Piece Cylinder cover MT184.10.06.002 EN-GJL-200
41 1 Piece Air chamber MT184.10.06.003 EN-GJL-200
42 1 Piece Water plug MT184.10.06.004 CuZn39Pb2
43 1 Piece Air chamber stud bolt MT184.10.06.005 9SMn28K
44 1 Piece Cylinder pipe MT184.10.06.006 X6CrNi18-10
45 1 Piece Cap nut DIN 1587-M12 CuZn39Pb3
46 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
47 1 Piece Membrane safety valve SV.01-065.7,5 F3000.4
Spike
48 2 Piece Straight flange G1“ MT184.10.06.010 EN-GJL-200
49 1 Piece Poppet valve body MT184.10.08.001
50 2 Piece Valve bridge MT184.10.06.008 X14CrMoS17
51 1 Piece Cylinder cover seal MT184.10.06.009 SBR/B-870M
Item Quantity
Unit Name Item number / Standard
Comments
Tab. 7.1 Spare parts list
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52 2 Piece Flat washer ISO 7089 -8 8-A2
53 2 Piece Hexagon nut ISO 4032-M8 8-A2
54 1 Piece Air chamber seal MT184.10.06.011 SBR/B-870M
55 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
56 2 Piece Stud bolt MT184.10.06.012 X17CrNi16-2
57 2 Piece Stud bolt MT184.10.06.013 X17CrNi16-2
58 2 Piece Seal DIN 7603-A-13x18x1,5
PVC
59 4 Piece Valve seat seal MT184.10.06.014 SBR/B-870M
60 3 Piece Hexagon screw ISO 4017-M6x16 8.8-A2
61 3 Piece Hexagon screw ISO 4017-M8x25 8.8-A2
62 2 Piece Seal MT184.10.06.015 SBR/B-870M
63 1 Piece Plain washer MT184.10.06.016 X17CrNi16-2
64 1 Piece Seal DIN 7603-A-13x18x1,5
PVC
65 1 Piece Seal DIN 7603-A-39x49x2
EPDM
66 1 Piece Valve seat MT184.10.07.001 CuZn40Al2
67 1 Piece Seal in valve seat MT184.10.07.002 80 NBR 180
68 1 Piece Delivery side valve pin MT184.10.01.001 CuZn39Pb3
69 1 Piece Delivery side valve seat Mt184.10.01.002 CuZn39Pb3
70 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
71 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
72 1 Piece Intake side valve pin MT184.10.02.001 CuZn39Pb3
73 1 Piece Intake side valve seat MT184.10.02.002 CuZn39Pb3
74 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
Item Quantity
Unit Name Item number / Standard
Comments
Tab. 7.1 Spare parts list
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75 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
76 1 Piece Hexagon nut ISO 10511.M6 A2
77 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
78 1 Piece Rocker shaft MT184.10.00.001 X14CrMoS17
79 1 Piece Rocker shaft with thread MT184.10.00.002 X14CrMoS17
80 4 Piece Insulating bush MT184.10.00.003 GP-22
81 1 Piece Motor clamp rail left MT184.10.00.004 EN-GJL-200
82 1 Piece Motor clamp rail right MT184.10.00.005 EN-GJL-200
83 1 Piece V-belt pulley MT184.10.00.006 EN-GJL-200
84 1 Piece Hexagon screw ISO 4017-M8x25 8.8
85 5 Piece Hexagon nut ISO 4032-M8 8
86 2 Piece Flat washer ISO 7089-A-8 140 HV
87 3 Piece Hexagon screw ISO 4017-M6x-10 8.8
88 1 Piece Valve housing complete MT184.00.06.000
89 1 Piece Crankcase complete MT184.00.09.000
90 1 Piece Intake valve complete MT184.00.01.000
91 1 Piece Pressure valve complete MT184.00.02.000
92 1 Piece Valve seat MT184.00.07.000
Item Quantity
Unit Name Item number / Standard
Comments
Tab. 7.1 Spare parts list
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7.2 Worksheet 1: Introduction to the piston pump, page 1
Objective:
To obtain an overview of the design and function of the piston pump.
Exercise:
You are provided with an assembled pump. Dismantle the pump so that allthe component parts are laid out before you.
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Worksheet 1, page 2
Pick up the pump drawings and the parts list. Locate the components in thedrawings. Refer to the parts list to find out the correct names of thecomponents.
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Worksheet 1, page 3
You are now familiar enough with the overall design of the pump to be ableto answer the following questions:
1. With what type of displacement device is the pump fitted?
With a dual sleeved piston.
2. Does a piston pump have a specific direction of rotation? Or are clockwiseand anti-clockwise both possible?
The pump delivery is independent of the direction of rotation of the drive.However, optimum lubrication of the gearbox can only be effected in thedirection indicated by the arrow on the pump.
3. Can you explain the basic operating principle of a piston pump?
The enlargement of the delivery chamber creates a negative pressure andthe pumped liquid is drawn in via the intake valve. The subsequentreversal of stroke reduces the size of the pump chamber and the pistondisplaces the liquid by way of the pressure valve.
4. Look at the materials in the parts list. For which media could the pump besuitable?
Because of the materials used in it, the piston pump is used in particularto pump non-aggressive, fluid media, such as drinking water and domesticwater.
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7.3 Worksheet 2: Design, function and applications of the piston pump, page 1
Objective:
To explain the design of the pump. To understand and describe its method ofoperation and usage.
Exercise:
1. Describe the design of the pump.
Use the drawings.
The motor is mounted on the pump unit by clamp rails.
The crankshaft, the connecting rod and the crosshead are automaticallylubricated in the gearbox housing by circulating oil on every rotation.
The piston rod is sealed off from the delivery chamber by a packing gland.
The sleeved pistons made of NBR rubber run in a stainless steel cylinderbushing.
The two delivery chambers each contain two disk valves with valve rubberplates.
The delivery side of the pump is executed as an air chamber with a built-in safety valve.
2. Name the five key components.
Pump housing, gearbox housing, valves, piston, packing gland.
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Worksheet 2, page 2
3. Explain the method of operation of the pump. Explain the deliveryprinciple.
On every revolution, the crankshaft acts by way of the connecting rod andthe crosshead on the piston, which is mounted on the end of the piston rod.This stroke motion causes the piston to move back and forth in the cylinderbushing.
On every stroke the piston enlarges and reduces the size of the deliverychamber. In the enlarging delivery chamber a negative pressure iscreated, causing the pressure valve to close and liquid to flow via theintake valve into the delivery chamber. In the reducing delivery chamberthe piston presses the liquid via the pressure valve out of the pump body,while at the same time the intake valve is pressed closed.
4. In what areas is the piston pump used?
Piston pumps are used primarily to transport fluids at high deliverypressures and low flow rates.
Typical applications include pumping drinking water and domestic water inresidential areas, in agriculture, onboard ships, in industry and atcommercial garden centres.
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7.4 Worksheet 3: Identifying causes of faults, page 1
Objective:
To identify or suspect likely causes of faults in response to specificmalfunctions while the pump is operating.
Exercise:
Try to find the causes of the faults listed in the table below. Note down yourassumptions in the right-hand section of the table. You can exclude system-related disturbances.
Fault Suspected cause
Medium leaking from pump body Packing gland worn
Housing seals defective
Running noise has markedly increased Bearing damaged
Crankshaft or piston rod deformed
Oil filling too low
The pressure difference usually generated between the inlet and outlet is no longer being attained
The pressure difference is much less than normal
Pump valves leaking
Foreign bodies in the pump
Piston worn
The pump housing has a much higher surface temperature than normal
Crankshaft, bearing and crosshead damaged
Oil filling too low
The current consumption of the drive motor has increased significantly compared to normal operating conditions
Motor defective
Gearbox components defective
Service life of piston too short Foreign bodies in the pump
Dry running
Inadequate material resistance
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7.5 Worksheet 4: Sealing systems, page 1
Objective:
To divide sealing systems into basic categories and identify them based onthe example of the pistons.
Information: Sealing systems we can find in pumps are classified as follows:
Static seals
(seals subject to stationary stress)
Dynamic seals
(seals subject to motion)
Sealing systems
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Worksheet 4, page 2
Exercise:
1. Here you see the sectional drawing of the pump.
• In the sectional drawing, mark the static seals as S and the dynamicseals as D.
• What functions do the static and dynamic seals perform?
The static seals seal the housing.
The dynamic seals seal moving parts.
S
D
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Worksheet 4, page 3
When you have identified the sealing systems used in the piston pump, moveon to the following exercise.
2. Describe the design and method of operation of a shaft seal based on thefloating ring principle.
Floating ring seals are contact seals which create a yielding sealconnection between stationary and rotating contact faces. There is a filmof liquid between these contact surfaces. The film of liquid assumes astable position due to the centrifugal force occurring during rotation.
Static elastomer seals seal the floating ring seal from the housing. Therotating floating ring is held axially to the counter ring by a spring, which isfixed in the housing.
3. Look at a shaft seal based on the packing gland principle and describe it.
The gland packing is a woven cord mainly made of solid fabrics. It isdeformed in the packing space between the shaft and the housing by anaxial force and so pressed onto the surfaces being sealed.
A sleeve is fitted to protect the shaft. Locking rings or ancillary glands holdthe packing in place. The gland press compresses the packing by way ofscrew fittings.
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7.6 Worksheet 5: Inspection of pumps, page 1
Objective:
To know what the term “inspection” involves, and to draw up an inspectionplan.
Exercise:
1. What does the term “inspection” mean in the context of technicalmaintenance?
Mark the statements you consider to be true or false in the Yes or Nocolumn of the following table as appropriate.
Activity Yes No
The current actual status of a pump is recorded and assessed X
Components such as pistons or seals are replaced as a preventive maintenance measure
X
Shaft bearings are lubricated and couplings re-aligned X
Entire pump units are replaced X
An inspection is always carried out with the system stopped X
During an inspection operating data of the pump system are measured (read) and entered in an inspection plan
X
An inspection can be seen as equivalent to preventive repair X
Inspection is a routine operation in machinery and plant maintenance X
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Worksheet 5, page 2
When you have established what the term “inspection” means, move on tothe following exercise.
2. Imagine we were talking about a vital piston pump in a domestic waterprocess. Let’s also assume that this pump is similar in design to the pumpfrom our MT 184 practice kit.
Draw up an inspection plan by mean of which an inspection can bedocumented.
Inspection plan
Pump: Inspected by:
Serial no.: Date:
Item Comments
Pump capacity
Delivery pressure
Leakage
Noise
Smooth running
Temperature
General condition
Oil level
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7.7 Worksheet 6: Servicing of pumps, page 1
Objective:
To know what is meant by the term “servicing”.
Exercise:
1. What does the term “servicing” mean in the context of technicalmaintenance?
Mark the statements you consider to be true or false in the Yes or Nocolumn of the following table as appropriate.
Activity Yes No
Components such as pistons, rod seals and gaskets are replaced as a preventive maintenance measure
X
The object of servicing is to record and assess the current actual status of a pump
X
Servicing of a pump is a routine operation, carried out at predetermined intervals
X
A service is usually carried out with the system stopped X
Servicing can be seen as equivalent to preventive repair X
During a service, packing glands are repositioned, couplings adjusted or oil fillings changed for example
X
Entire pump units are replaced X
Servicing is always carried out when damage to a pump is identified
X
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Worksheet 6, page 2
When you have established what the term “servicing” means, move on to thefollowing exercise.
2. Do you think that routine servicing is useful and necessary for the pistonpump from our MT 184 practice kit?
Give reasons for your decision.
Yes! During servicing, the condition of the wearing parts is checked andthe parts are replaced as necessary. For the piston pump from MT 184 theparts are the piston, the housing seals, the valves, the packing gland andthe oil filling of the main gearbox.
3. Let’s assume that two piston pumps with the classic differing shaft sealsare being used in a domestic water process.
What servicing operations need to be carried out on the packing gland typeshaft seal and on the floating ring seal type?
Packing glands must be repositioned depending on the leakage rate. Theirgeneral condition must be checked and they must be repacked asnecessary.
Floating ring seals do not have to be adjusted. However, at each servicethe condition should be checked and, depending on the importance,replaced as a preventive measure.
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7.8 Worksheet 7: Repairs to pumps, page 1
Objective:
To know what is meant by the term “repairs” in this context and to draw up apreventive maintenance plan.
Exercise:
1. What does the term “repairs” mean in the context of technicalmaintenance?
Mark the statements you consider to be true or false in the Yes or Nocolumn of the following table as appropriate.
Activity Yes No
Repairs involve replacing well-used parts with new ones, for example pistons and seals
X
Repairs are carried out when damage has occurred to the pump X
Repairs may also be carried out as routine and preventive maintenance measures to prevent damage and stoppages from occurring in the first place
X
Entire pump units are replaced X
Preventive maintenance can prevent a pump from failing X
Repairs are normally carried out with the system stopped X
If servicing is carried out on a regular basis, repairs are not needed X
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Worksheet 7, page 2
When you have established what the term “repairs” means, move on to thefollowing exercise.
2. Let us assume that our piston pump represents an important assembly ina domestic water process. A failure of the pump would result in the entireline being shut down.
In view of this, the pump is inspected and serviced at regular intervals.
To achieve the most reliable operation possible, the plant managementdecides to carry out routine preventive repairs to the unit.
Draw up a repair order for carrying out and documenting the work.
Use the drawings.
Inspection order
Pump: Inspected by:
Serial no.: Date:
Procedure Comments/Status
Parts to be replaced:
Valve rubber plate (70, 74)
Valve seat seal (59)
Air chamber seal (54)
Connection seals (62)
Cylinder cover seals (51)
Piston (14)
Packing gland packs (34)
Lip seal (35)
Oil filling
Parts to be checked:
Housing components
Bearings
Piston Rod
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7.9 Worksheet 8: Wearing parts on the piston pump, page 1
Objective:
To identify the wearing parts on the piston pump.
Exercise:
1. Mark the wearing parts on the pump drawing and name them by way ofexample.
Air chamber seal Cylinder seal Connection seal Valve seat seal
Glandpacking
Lip seal Piston Valve rubber plate
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Worksheet 8, page 2
2. Of what material are the wearing parts of the piston pump made?
Enter the wearing parts from the previous page in the table with theirmaterial data or standard designations.
Wearing part Material
Gland packing PTFE-saturated
Lip seal A2 - 70
Piston NBR
Valve rubber plate NBR-45° Shore A
Air chamber seal, cylinder seal, connection seal, valve seat seal
SBR/B-870M
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7.10 Worksheet 9: Assembling the piston pump, page 1
Objective:
To structure the assembly process. To identify which assembly units andphases can be compiled.
Exercise:
You have laid out all the component parts of the piston pump in front of you.Your task is to assemble the pump.
To do this, first assembly individual assembly units. Then combine theassembly units to create the overall system in a sequence of assemblyphases.
1. Collect the components from which you can compile assembly units andphases. Name the assembly units and phases.
Use the drawings.
• Assembly unit 1 – Crankshaft
Item Name
3 Crankshaft
24 Grooved ball bearing
25 Grooved ball bearing
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Worksheet 9, page 2
• Assembly unit 2 – Connecting rod with piston rod
• Assembly unit 3 – Packing gland
• Assembly unit 4 – Intake valve
Item Name
1 Connecting rod
26 Crosshead
27 Piston Rod
28 Straight pin
29 Hexagon nut
30 Hexagon screw
31 Hexagon nut
Item Name
2 Packing gland housing
32 Packing gland screw
33 Brass washer
34 Gland packing
35 Lip seal
Item Name
72 Intake side valve pin
73 Intake side valve seat
74 Valve rubber plate
75 Hold-down
76 Hexagon nut
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Worksheet 9, page 3
• Assembly unit 5 – Pressure valve
• Assembly unit 6 – Gearbox
Item Name
68 Delivery side valve pin
69 Delivery side valve seat
70 Valve rubber plate
71 Hold-down
Item Name
A Assembly unit 1
B Assembly unit 2
C Assembly unit 3
5 Gearbox housing
6 Bearing cover, closed
7 Gearbox cover
9 Oil splash guard
10 Packing gland seal
11 Bearing cover seal
12 Oil stripper
13 Oil plug
14 Duo-piston
17 Hexagon nut
18 Spring ring
19 Hexagon screw
21, 22 Angled oiler with nut and seal
4, 23 Bearing cover, open, with radial shaft seal
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Worksheet 9, page 4
• Assembly unit 7 – Pump housing
Item Name
D Assembly unit 4
E Assembly unit 5
40 Cylinder cover
41 Air chamber
42, 58 Water plug with seal
43 Air chamber stud bolt
54 Air chamber seal
59 Valve seat seal
60 Hexagon screws
61 Hexagon screws
62 Seal
45, 63 Cap nut with washer
46, 77 Drain plug with seal
47, 65 Membrane safety valve with seal
48 Straight flange G1“
49, 64 Poppet valve body with seal
50 Valve bridge
51 Cylinder cover seal
52, 53 Hexagon nut with washer
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Worksheet 9, page 5
2. When you have put together the various assembly units, the next step isto assemble the pump.
You should carry out this phase and represent it in a structurecorresponding to the pattern shown.
Set out the identified assembly phases through to the complete pump.
Parts x, y, ...
Parts x, y, ...
Gearing
Piston pump
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Worksheet 9, page 6
Procedure for assembling the piston pump
Pump housing(assembly unit 7)
Hexagon nutwith washer(item 85, 86)
Gearbox(assembly unit 6)
Disk spring(item 15)
V-belt pulley withhexagon screw(item 83, 87)
Rocker shaft(item 78)
Hexagon screwitem 87
Motor clamp railleft and right(item 81, 82)
Rocker shaftwith gearbox
(item 79)
Piston pump
Hexagon screwwith hexagon nut
(item 84, 85)
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7.11 Worksheet 10: Piston replacement, page 1
Objective:
Planning and execution of piston replacement on a piston pump.
Exercise:
1. Your task is to replace the piston on a piston pump.
Set out your method in the pre-compiled work plan. Use the drawings.
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Worksheet 10, page 2
Work plan
Name: Piston pump – Piston replacement
Date: Carried out by:
Order no.: Date:
Procedure
Procedure Tools
Dismantling
1 Unscrew hexagon nut and washer (85, 86) from stud bolts and detach packing gland (assembly unit 3) from pump
Wrench size 13
2 Unscrew hexagon nut (85) from stud bolts Wrench size 13
3 Pull pump housing (assembly unit 7) from gearbox (assembly unit 6). Carefully guide piston out of cylinder pipe when doing so
4 Unscrew hexagon nut with spring ring (17, 18) from duo-piston (14)
Wrench size 13
5 Pull duo-piston from piston rod (27)
Assembly
6 Fit duo-piston onto piston rod
7 Screw hexagon nut with spring ring (17, 18) against duo-piston
Wrench size 13
8 Grease piston
Place pump housing (assembly unit 7) against gearbox (assembly unit 6). Carefully guide piston into cylinder pipe when doing so
9 Screw together pump housing and gearbox with hexagon nut (85) and pre-assembled stud bolts
Wrench size 13
10 Fit packing gland (assembly unit 3) with hexagon nut and washer (85, 86) on stud bolts
Wrench size 13
Estimated time required: 20 min
7 Solutions 196
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7.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1
Objective:
To assign items from a spare parts list to a spare parts drawing.
Exercise:
You are given a spare parts drawing on which the item numbers have not yetbeen entered. Refer to the supplied spare parts list.
Enter the item numbers from the 1st column of the spare parts list in the fieldsin the spare parts drawing.
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Worksheet 11, page 2
Fig. 7.4 Spare parts drawing for the piston pump
83, 8
7
81, 8
2
79, 8
084
, 85
8779
, 80
85, 8
6
8
7 Solutions 198
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Worksheet 11, page 3
Fig. 7.5 Spare parts drawings for the gearbox
19
6
22
21
4, 23
16
11
3 - 15
8
20
10
3435 14
171833
2
321227913 29282657 1 30,31 24 25
7 Solutions 199
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Worksheet 11, page 4
Fig. 7.6 Spare parts drawings for the pump housing
4245 63 43
4060
51
50, 5
2, 5
3
59
39
65
47
4861
7462
46, 7
776757372
4767
6658
41
54 68
69
7071
4457
58
3849
373664
7 Solutions 200
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Worksheet 11, page 5
Item Quantity
Unit Name Item number / Standard
Comments
1 1 Piece Connecting rod MT184.10.04.001
2 1 Piece Packing gland housing MT184.10.05.002
3 1 Piece Crankshaft MT184.10.03.001
4 1 Piece Bearing cover, open MT184.10.10.001
5 1 Piece Gearbox housing MT184.10.09.001 EN-GJL-200
6 1 Piece Bearing cover, closed MT184.10.09.002 EN-GJL-200
7 1 Piece Gearbox cover MT184.10.09.003 DOC04
8 1 Piece Base plate MT184.10.09.004 S235JR
9 1 Piece Oil splash guard MT184.10.09.005 DOC04
10 1 Piece Packing gland seal MT184.10.09.006 SBR/B-870M
11 2 Piece Bearing cover seal MT184.10.09.007 SBR/B-870M
12 1 Piece Oil stripper MT184.10.09.008 60NBR693 SW
13 1 Piece Oil plug MT184.10.09.009 CuZn39Pb3
14 1 Piece Duo-piston PM10 Simirit
15 1 Piece Disk spring DIN 6888-5x7,5
16 8 Piece Hexagon nut ISO 4032-M6 8
17 2 Piece Hexagon nut ISO 4032-M8 8
18 1 Piece Spring ring DIN 127-A-8 A2
19 6 Piece Hexagon screw ISO 4017-M6x12 8.8
20 4 Piece Rubber buffer 500029 GMT
21 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
22 2 Piece Angled oiler with nut G1/8 Spike
23 1 Piece Radial shaft seal DIN 3760-A-16x35x7
NBR
24 2 Piece Grooved ball bearing DIN 625-6202
25 1 Piece Grooved ball bearing DIN 625-6203
Tab. 7.2 Spare parts list
7 Solutions 201
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Worksheet 11, page 6
Item Quantity
Unit Name Item number / Standard
Comments
26 1 Piece Crosshead MT184.10.04.002 EN-GJL-200
27 1 Piece Piston Rod MT184.10.04.003 X14CrMoS17
28 1 Piece Straight pin ISO 8734-12x35 C1
29 1 Piece Hexagon nut ISO 4032-M8 8-A2
30 1 Piece Hexagon screw ISO 4017-M6x25 8.8
31 1 Piece Hexagon nut ISO 4032-M6 8-A2
32 1 Piece Packing gland screws MT184.10.05.002 CuZn39Pb3
33 1 Piece Brass washer MT184.10.05.003 CuZn37F30
34 1 Piece Gland packing 00.2251 Spike
35 1 Piece Lip seal ISO 4032-M8 A2-70
36 1 Piece Lock nut MT184.10.09.002 CuZn39Pb2
37 1 Piece Knurled screw MT184.10.08.003 CuZn39Pb3
38 1 Piece Cap MT184.10.08.004 NBR
39 1 Piece Pump housing MT184.10.06.001 EN-GJL-200
40 1 Piece Cylinder cover MT184.10.06.002 EN-GJL-200
41 1 Piece Air chamber MT184.10.06.003 EN-GJL-200
42 1 Piece Water plug MT184.10.06.004 CuZn39Pb2
43 1 Piece Air chamber stud bolt MT184.10.06.005 9SMn28K
44 1 Piece Cylinder pipe MT184.10.06.006 X6CrNi18-10
45 1 Piece Cap nut DIN 1587-M12 CuZn39Pb3
46 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
47 1 Piece Membrane safety valve SV.01-065.7,5 F3000.4
Spike
48 2 Piece Straight flange G1“ MT184.10.06.010 EN-GJL-200
49 1 Piece Poppet valve body MT184.10.08.001
50 2 Piece Valve bridge MT184.10.06.008 X14CrMoS17
Tab. 7.3 Spare parts list
7 Solutions 202
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Worksheet 11, page 7
Item Quantity
Unit Name Item number / Standard
Comments
51 1 Piece Cylinder cover seal MT184.10.06.009 SBR/B-870M
52 2 Piece Flat washer ISO 7089 -8 8-A2
53 2 Piece Hexagon nut ISO 4032-M8 8-A2
54 1 Piece Air chamber seal MT184.10.06.011 SBR/B-870M
55 2 Piece Seal DIN 7603-A-10x13,5x2
PVC
56 2 Piece Stud bolt MT184.10.06.012 X17CrNi16-2
57 2 Piece Stud bolt MT184.10.06.013 X17CrNi16-2
58 2 Piece Seal DIN 7603-A-13x18x1,5
PVC
59 4 Piece Valve seat seal MT184.10.06.014 SBR/B-870M
60 3 Piece Hexagon screw ISO 4017-M6x16 8.8-A2
61 3 Piece Hexagon screw ISO 4017-M8x25 8.8-A2
62 2 Piece Seal MT184.10.06.015 SBR/B-870M
63 1 Piece Plain washer MT184.10.06.016 X17CrNi16-2
64 1 Piece Seal DIN 7603-A-13x18x1,5
PVC
65 1 Piece Seal DIN 7603-A-39x49x2
EPDM
66 1 Piece Valve seat MT184.10.07.001 CuZn40Al2
67 1 Piece Seal in valve seat MT184.10.07.002 80 NBR 180
68 1 Piece Delivery side valve pin MT184.10.01.001 CuZn39Pb3
69 1 Piece Delivery side valve seat Mt184.10.01.002 CuZn39Pb3
70 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
71 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
72 1 Piece Intake side valve pin MT184.10.02.001 CuZn39Pb3
73 1 Piece Intake side valve seat MT184.10.02.002 CuZn39Pb3
Tab. 7.4 Spare parts list
7 Solutions 203
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Worksheet 11, page 8
Item Quantity
Unit Name Item number / Standard
Comments
74 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A
75 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3
76 1 Piece Hexagon nut ISO 10511.M6 A2
77 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2
78 1 Piece Rocker shaft MT184.10.00.001 X14CrMoS17
79 1 Piece Rocker shaft with thread MT184.10.00.002 X14CrMoS17
80 4 Piece Insulating bush MT184.10.00.003 GP-22
81 1 Piece Motor clamp rail left MT184.10.00.004 EN-GJL-200
82 1 Piece Motor clamp rail right MT184.10.00.005 EN-GJL-200
83 1 Piece V-belt pulley MT184.10.00.006 EN-GJL-200
84 1 Piece Hexagon screw ISO 4017-M8x25 8.8
85 5 Piece Hexagon nut ISO 4032-M8 8
86 2 Piece Flat washer ISO 7089-A-8 140 HV
87 3 Piece Hexagon screw ISO 4017-M6x-10 8.8
88 1 Piece Valve housing complete MT184.00.06.000
89 1 Piece Crankcase complete MT184.00.09.000
90 1 Piece Intake valve complete MT184.00.01.000
91 1 Piece Pressure valve complete MT184.00.02.000
92 1 Piece Valve seat MT184.00.07.000
Tab. 7.5 Spare parts list
7 Solutions 204
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7.13 Worksheet 12: Spare parts ordering, page 1
Objective:
To place a technically unambiguous spare parts order.
Exercise:
You are going to carry out a repair, and need replacement parts for yourpiston pump.
Select three parts and make a spare parts order.
Use the documents provided.
Spare parts order for pump:
Type: PM 10
Serial no.:
Parts:
1 x duo-piston Item 14
4 x valve rubber plate Item 70
1 set of gland packs Item 34
7 Solutions 205
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8 Index
A
Assembly phase 1 – Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 120Assembly phase 2 – Connecting rod with piston rod . . . . . . . . . . 65, 119Assembly phase 3 – Packing gland . . . . . . . . . . . . . . . . . . . . . . . 69, 118Assembly phase 4 – Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . 73, 117Assembly phase 5 – Pressure valve . . . . . . . . . . . . . . . . . . . . . . . 77, 116Assembly phase 6 – Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81, 113Assembly phase 7 – Pump housing . . . . . . . . . . . . . . . . . . . . . . . 91, 110Assembly phase 8 – Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 107
C
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 8, 29Centrifugal pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29Characteristic curve, pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Characteristic curve, system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
D
Diaphragm pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 11, 30Dynamic seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F
Floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
G
Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14, 32
H
Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
I
Inline centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 13, 31Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Intake characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8 Index 206
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M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Multi-flow pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Multiple-stage pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Multi-stage centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29
O
Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
P
Packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Parallel configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 12, 31, 46, 59Piston pump dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Piston pump spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Piston pump spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Piston rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 41Piston seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Positive-displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14Pump characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pump, multi-flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
R
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 34Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
S
Screw pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 10, 30Seals, dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Seals, floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Seals, packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 49Seals, static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Series configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Standard centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34System characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Index 207
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T
Technical data of piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
V
Valves in pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 Index 208
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9 Drawings
Name Drawing number
Layout MT184.00.00.000
Spare parts list MT184.00.00.000
Piston pump – Drawing MT184.00.00.000
Piston pump – Parts list MT184.00.00.000
Pressure valve, complete – Drawing MT184.00.01.000
Pressure valve, complete – Parts list MT184.00.01.000
Intake valve, complete – Drawing MT184.00.02.000
Intake valve, complete – Parts list MT184.00.02.000
Crankshaft with bearing – Drawing MT184.00.03.000
Crankshaft with bearing – Parts list MT184.00.03.000
Connecting rod with piston – Drawing MT184.00.04.000
Connecting rod with piston – Parts list MT184.00.04.000
Packing gland complete – Drawing MT184.00.05.000
Packing gland complete – Parts list MT184.00.05.000
Valve housing complete – Drawing MT184.00.06.000
Valve housing complete – Parts list MT184.00.06.000
Seat valve – Drawing MT184.00.07.000
Seat valve – Parts list MT184.00.07.000
Poppet valve – Drawing MT184.00.08.000
Poppet valve – Parts list MT184.00.08.000
Crankcase, complete – Drawing MT184.00.09.000
Crankcase, complete – Parts list MT184.00.09.000
Flange with seal – Drawing MT184.00.10.000
Flange with seal – Parts list MT184.00.10.000
Rocker shaft MT184.10.00.001
Rocker shaft with thread MT184.10.00.002
Insulating bush for motor rockers MT184.10.00.003
9 Drawings 209
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Motor clamp rail left MT184.10.00.004
Motor clamp rail right MT184.10.00.005
Pump V-belt rail MT184.10.00.006
Delivery side valve pin MT184.10.01.001
Delivery side valve seat MT184.10.01.002
Valve rubber plate MT184.10.01.003
Hold-down MT184.10.01.004
Intake side valve pin MT184.10.02.001
Crankshaft MT184.10.03.001
Connecting rod MT184.10.04.001
Crosshead MT184.10.04.002
Piston Rod MT184.10.04.003
Packing gland housing MT184.10.05.001
Packing gland screw MT184.10.05.002
Brass washer MT184.10.05.003
Valve housing MT184.10.06.001
Cylinder cover MT184.10.06.002
Air chamber MT184.10.06.003
Water plug MT184.10.06.004
Air chamber stud bolt MT184.10.06.005
Cylinder pipe MT184.10.06.006
Oil plug MT184.10.06.007
Valve bridge MT184.10.06.008
Cylinder cover seal MT184.10.06.009
Straight flange G1“ MT184.10.06.010
Air chamber seal MT184.10.06.011
Stud bolt MT184.10.06.012
Stud bolt MT184.10.06.013
Name Drawing number
9 Drawings 210
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Valve seat seal MT184.10.06.014
Flange seal MT184.10.06.015
Plain washer MT184.10.06.016
Valve seat MT184.10.07.001
Seal in safety valve seat MT184.10.07.002
Poppet valve body MT184.10.08.001
Lock nut for poppet valve MT184.10.08.002
Knurled screw for poppet valve MT184.10.08.003
Cap MT184.10.08.004
Drive frame MT184.10.09.001
Bearing cover, closed MT184.10.09.002
Gearbox cover MT184.10.09.003
Base plate MT184.10.09.004
Oil splash guard MT184.10.09.005
Seal for packing gland MT184.10.09.006
Bearing cover seal MT184.10.09.007
Oil stripper MT184.10.09.008
Oil plug without thread MT184.10.09.009
Bearing cover, open MT184.10.10.001
Name Drawing number
9 Drawings 211