P 1 / 34

TOSHIBA E KC00308 5-a

INSTRUC.,r-ION MANUAL

SEAL OIL PUMP

(MAIN SEAL OIL PUMP) (EMERGENCY SEAL OIL PUMP)

NOTE

READ THESE INSTRl CTIONS CAREFULLY

SAVE THESE INSTRUCTIONS

TDS HIBA CORPORATION .

The information in this material is cc nfidential and contains Toshiba's intellectual incl Jdina know-how. It shall not be disclosed to anv third party, copied, reproduced, used for unauthorized purpose nor modified without prior written consent of Toshiba. Toshiba Corpore tion

z01586n0

P 2 / 34

INSTRUCTION MANUAL

THREE PINDLE SCREW PUMP

MAIN SEAL IL PUMP (GH-R1T-214) EMERGENCY SE OIL PUMP (GH-R1T168)

Ltd. P3M-35562 P3M-35563

P 3 / 34

Safety instruction

The Foreward

1. Introduction 1. 1 Outline 1. 2 Denotation of pump t e

2. Structure

3. Installation and piping 3. 1 Installing place 3. 2 Foundation 3. 3 Installation

Table of content

3. 4 Installing suction pi pi g .. 3. 5 Installing discharge pi ing : 3. 6 Alignment ... .-.............. , ..................................... .

4. Operation 4. 1 Preparation for operati n 4. 2 Operation start 4. 3 During operation 4. 4 Stopping

5. Maintenance and inspecti n 5. 1 Maintenance 5. 2 Periodical maintenance 5. 3 Allowance

Pa e 1

2

3 3 4

5

6 6 6 6 7 7 8

9 10 10 10 11

12 12 13 14

6. Causes of trouble and cou ter measures .. .. .. .... .. 15

7. Disassembling and reasse 7. 1 Disassembling 7. 2 Reassembling

8. Drawing

bling .. .. .. .. .. .. .. 16 16 17

18

P 4 / 34

afety Instructions

autions for your safety

Before using this pump, read th instruction manua I. Fo II ow warning I abe I, instruction and caution plate in order to us it correctly. It is also highly recommendedto alw ys keep the instruction manual at the same place for easy access. Transportation, i nsta II at ion, piping, wiring, operation, inspection and rna i ntena ce

work must be done by on I y a I ice sed and I or authorized person who has enough know I e ge on health and safety- rules and regulations as well as on his or her profession.

In any respect, we wi I I not gu rantee any death, injuries, damages and losses which are resu It in modification wit out our written authorization or using and assemb I i ng unauthorized parts.

When disposing a pump, any ac essories, used parts and oi I, they should be trea ed as a general industrial waste. Warning label and sign in the i struction manual are classified into war~ing, caut on

and notice as descr i bed be low.

WARNING

Lh. CAUTION

lndicat s a potentially hazardous situation which, if not avoided, could suit in death or serious injury.

lndicat s a potentially hazardous situation which, if not avoided, may re ult in minor or moderate injury.

I lin. dicat s a potentially hazardous situation which, if not avoided,

/\. NOTICE may re ult in damaging or defecting a product It will be only use ~ for pro ecting the property, but not for personal safety. ~--------------~

1

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The foreword

1. This instruction manual is o understand the correct handling method of equipment. Read and unde stand the contents of the instruction manual be ore operation and maintenance ork.

2. The instruction manual is i tended to cover all the situations of operation and maintenance. When any que tion or inquiry arises concerning the content of the instruction manual, contact osaka Laboratory Ltd.

3. The content ofthe instructi n manual is the property ofKosaka Laboratory Ltd. and is strictly confidential to nauthorized personnel or any third party.

4. The 'mailing address, the items to identify the products and the necess ry information for trouble shoot ng are as follows.

1) The mailing address

KOSAKA LABORATORY TD. TOKYO HEAD OFFICE ALES DEPT.

Mikuni East Bldg., 6-13 10, Sotokanda, Chiyoda-ku, Tokyo 101-0021 JAP TEL: 03-5812-2011 (J AN), FAX: 03-5812-2015 (JAPAN)

2) Inquiry contents Serial number, Pump na e, Type, Capacity, and Discharge pressure. Explanation on abnorm l occurrence together with the preceding and curr nt situation.

5. Delivery Inspection Inspect the following immed ately after the delivery of the pump.

1) No damage during transp rtation. 2) Specification matches the required specification. 3) No missing of accessories nd spare parts.

If any question arises, plea e contact to the supplier.

2

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1. Introduction

Do not moe ify the equipment without the written consent of

WARNING

KosakaLa poratory Ltd.

Understan ~ the content of the instruction manual thoroughly before any work. When maintenance covers equipment with an electric motor, cut the electricity supply switch off.

1.1 Outline Kosaka three spindle scr ~w pump is designed and manufactured on the base of

the advanced technology b acked up by the long historical experience. The pum1 is a displacement type cons sting mainly of a power rotor, two idler rotors an( a

sleeve. The pump has the f ollowing features and is applicable for many fields.

The features are as follows: (1) Reliable operation

The simple structure e nsures the reliable and consistent operation. (2) High efficiency

The pump performs w 'th high efficiency because of low friction loss and 1 pw leakage.

(3) High suction Cavitation hardly occu rs because of the high suction capacity of the pump.

(4) Long life The optimal selection of pump materials and power-transfer through liq id

without contact betweer the power rotor and idler rotors assure the long life. (5) No pulsating flow

The pump operates wi h little vibration and low noise, because the dischar ed liquid forms perfectly co ntinuous flow without pulsating.

(6) Compact size The high-speed operati on makes the pump size compact.

<

''

3

P 7 / 34

1. 2 Denotation of pump type The denotation of pump t~pe is as follows.

GH- R2TL_

1

__ 2_~_4 __ _ Screw number Denotation of surface treatment and balance mech nism S : standard type T : nitriding treatment applied B :. nitriding treatment and balancing mechanism D : balance disk type (nitriding treatment and bal. ncing

mechanism)

Number of chambers kept closed by power and id er rotors.

Pump in which ball bearings are used (no symbol R given to the balance disk type though it is fitted cylindrical roller bearings.

Denotation of type of pump H : horizontal type V : vertical type C : flanged tvoe

Symbol ofKosaka three spindle screw pump

4

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2. Structure

The structure of the t ree spindle screw pump is shown on the draw ng "Sectional Assembly" in Ar icle 9. A shaft coupling transmits power from a nio or to the power rotor. The p wer rotor is supported with a front and a rear bearng, while the idler rotors are upported with a sleeve. The handling liquid lubrica es the plain bearings, therefo e external lubrication is unnecessary.

The mechanism of balanci g thrust load acting on the rotors is as follows.

Power rotor ; Thrust 1 ad is balanced by high-pressure liquid spouted fro a port mad in the power rotor to act on the end of the shaft.

Idler rotors ; Thrust 1 ad is balanced by high-pressure liquid acting on t e end of th balance piston.

When the handling liqui does not have sufficient lubricating property, the id er rotors contact with the sle ve to cause wear. In this case, surface treatment is applied to the power roto , the idler rotors and the sleeve to prevent wear. A certain type of pumps has a balance mechanism to apply the hydraulic press re between the idler rotors an the sleeve.

The structure of the main arts are as follows.

(1) Casing The casing is made in a b ock form with its inside divided into two chambers t

the discharge side and the uction side. The contacting positions of both the fro t and rear covers to the sl eve are machined concentrically, and the bearin s provided in each cover support the power rotor along the central axis of the sleev

(2) Power rotor The power rotor is a shaft ith screw machined on the shaft. The shaft transm s

driving force and the sere acts as a pump. The screw is a double-thread ty e and the lead of the screw is orie to two times of the outside diameter of the sere The power rotor with a long screw (multiple chambers) is applicable high-pressure operation.

(3) Idler rotor The idler rotors are als machined to have double-thread screws, outsi e

diameters are 3/5 of the po (4) Sleeve

The power rotor and idle rotors are inside of the sleeve, which is fixed to t casing. Since the power rot r and idler rotors rotate in the sleeve, the surface

the sleeve is machined and mished. (5) Bearings

The ball bearing and plain bearings are used. (6) Mechanical seal

The mechanical seal preve ts leakage of a liquid. (7) Ball valve ,

The ball valve prevents incoming of air into the pump. (8) Relief valve

The relief valve prevents t e abnormal increase of discharge pressure.

5

P 9 / 34

3 . Installation and piping

wARNIN

Transpor the equipment by licensed or authorized personnel with suffi ient knowledge. Special attention and caution are required hen fitting a hanging wire in relation to its weight and cente of gravity.

Do not pu a hand and a foot under heavy equipment. To neglec this instruction may result in pinch or injury.

3. 1 Installing place (1) Install a pump in a place to achieve easy operation, mainten

disassembling a:pd rea sembling. Do not put hands or feet under heavy w equipment.

3. 2 Foundation (1) Make concrete founda ion in an area with space 'and depth sufficient to b ar

the weight of a pump a d to prevent frost heaving, because concrete placed on soft ground may sink or tilt.

(2) Make a hole in the concrete foundation with sufficient clearance or embedding foundation olts according to the drawing or the size of actual bo ts level the surface ofthe oncrete.

(3) Install the pump after the concrete solidifies thoroughly.

3. 3 Installation (1) Place a common bed to ether with a pump and a motor on the foundation.

Insert metallic wedges between the bed and the foundation leaving suita le gap tobe filled with cern nt mortar later.

(2) Support the bed tho oughly as shown in Fig. 2. If the bed is partia ly supported as shown in igure 1, the pump may result in distortion.

GOOD

Figure 1 Figure 2

6

P 10 / 34

(3) Insert anchor bolts t rough the bed at the designed points, screw nuts to the. bolts to the top of the n ts and hang down the anchor bolts into holes.

Figure 3

(4) Check horizontal level fthe bed to meet the tolerance. (5) Charge cement mortar to fill up space under the common bed and the anc or

bolt holes. Wait for so 'dification of the concrete, 'and fasten the nuts of he anchor volts evenly.

3. 4 Installing suction pipin (1) Minimize length ofsu tion piping and the number of bending. Install pro er

supporting devices to ee the pump from the weight of the piping. (2) Do not make bends wi h small curvature radius, sharp change in diamete of

piping or sharp chan e of flow direction. Install a gasket at flange joi ts properly not to interru t the flow inside the piping.

(3) Do not allow any part of the piping rise in a form allowable to contain air in the piping. ,

(4) Install joints not to a ow leakage of air into the piping. Air in the pip ng may result in the pump failure.

(5) Install a strainer with more than 40-mesh or equivalent in the piping. (6) Position an intake o the pipe from the bottom of an oil tank to prev nt

sucking of sand or forei n objects. (7) Clean and remove for ign objects such as welding chips or scale remaining in

the piping. (8) Install a gate valve at he suction pipe for easy disassembling and inspectio .

Keep the valve open fu y while the pump is operating. The valve is only or disassembling and insp ction.

3. 5 Installing discharge pip ng (1) Install an air ventilat' on valve at the highest position in the piping. (2) Install a gate valve o the pipe at the pump for easy disassembling a d

inspection. Install pro er supporting devices to free the pump from the wei ht of the piping.

7

P 11 / 34

3. 6 Alignment Check shaft centering f a pump and a motor as follows. Clean the o

peripheral surface of coup ings with thinner or some suitable solvent. Measure deviation at four points o the periphery of the each coupling hubs as show Fig. 4. Adjust the shaft enter position and the surface gap of the pump and motor within the differenc in the measured values 0.1 mm under, by insertin adjusting liner. See separately attached i struction manual for the information concerning handling, installation and maintenance of coupling.

(1) With the dial gauge ounted on the driven shaft coupling hub, rotate . b th hubs together to check he centering, adjust if necessary (See figurEJ4- 0.

Figure 4- 1

(2) With the dial gauge m unted on a coupling hub, rotate both hubs together t check the gap between he flanges, adjust if necessary (See figure 4- 2).

Figure 4- 2

8

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4. Operation

Never a low unauthorized personnel to operate the pump. Do not tpuch or contact any rotating part.

Confirm the safety of personnel around the pump before operatiojn start.

/f"- Installll relief valve at the pump to secure safety. The "VWARNING pressurE ofthe pump without the reliefvalve may increase

excessiv~ly. Do not operate the pump without a coupling cover. To neglect this instruction may result in rolled in or injury. Keep clo~;hes off the pump during operation to prevent rolled 1n.

Do not t uch or contact sealing part and hot parts while the pump is in operation.

Check tl e leakage of piping during pump operation, and stop the pump immediately after detecting the leakage.

& CAUTION Reinstal a protection cover for rotating parts removed for inspecti< nor maintenance.

D. NOTICE

Do not t uch or contact the pump when the pump is under operatio p with high temperature. To neglect the instruction may res lt in burn.

Remove ~oupling bolts and check the rotating direction of the pump.

Jog the 1 ump to confirm the rotating direction when the coupling bolts are not removed.

Do not ~ tart the normal operation of the pump immediateHr after inf tallation. Rotate the pump with hands to confirrp. smooth otation, and operate the pump for a short time tp check se lleakage, abnormal vibration, noise, etc.

Stop the pump immediately after detecting abnormal thing. Check tl e cause of trouble, repair the trouble, and restart the operatio after confirming the safety.

Operate !valves and cocks according to the operation manual. Do not pperate valves and cocks improperly during pum operatio .

9

P 13 / 34

4. 1 Preparation for operation (1) Confirm valves of both suction side and discharge side open before operati< n

start. (2) Do not touch or conta~t any rotating parts, and keep clothes off rotating

parts.

Item

Installation

Alignment

Rotation

Liquid

Liquid temperature

Difference in temperature

Valves

Liquid in pump

Air bleeding

Direction

Table 2 Prenaration for oneration

Checkpoint

The pum1 is installed properly.

The moto and the pump are aligned satisfactorily.

The pumf rotates smoothly with hands.

The hand ing liquid meets the specification.

Fill the pipe with the liquid when piping has long distance between the tank and the inlet port of the pump.

The liquic temperature is within the range shown in the specificaf on.

The temp rature difference between the liquid and the pump casing is l~ss than 20C. If it is over, do not start the pump. The valve~ at both the discharge and the suction side are opened fu ly. Fill the pl mp with the liquid.

Evacuate ~ir in the piping. The pump rotates in the normal direction.

4. 2 Operation start (1) Stop a pump, if the pump does not suck liquid within 10 seconds af er

operation start. (2) Do not do dry running operation, which causes seizing of the rotary parts. (3) Check and confirm tl: e discharge and suction pressure within the desigr ed

pressure. (4) Run the difference betv een suction pressure and discharge pressure kept at

more than 0.2 MPa. (5) Measure the temperature of a casing and a bearing to check the lo ~al

temperature rise. rrhe temperature must be less than the ambi{ nt temperature plus 40C and less than the liquid temperature plus 20C.

(6) Confirm an electric current ofthe motor at a normal level.

4. 3 During operation (1) Follow all instructions given in 4 2 above during operation. (2) In case the liquid witl significantly different temperature from the curren~ly

handling liquid is supplied to the pump; keep changing ratio of the liq id temperature less than l0C for 20 minutes. The higher changing ratio may result in seizing of sere !vs.

10

P 14 / 34

(3) Check abnormal vibration of the pump. The allowable vibration depends on the speed as follows:

Speed (n inl) Vibration ( f.1 m) ALLSP~ED 20

(Double Amplitude)

(4) Check abnormal chan~ing noise of the pump. (5) Check leakage from the mechanical seal. The allowable amount ofleaking

liquid from the inechat ical seal is 3 m i !h.

4. 4 Stopping When a pump is stopped s a stand by pump for a high temperature liquid, k ~ep

the pump run reverse for fvarming up. The standard number of pump speed for warming up ranges from 3 0 to 60 min1

11

P 15 / 34

5 . Maintenance and inspection

Do not ~se any fire around the pump, when the himdling liquid i inflammal;lle. To neglect the instruction may result n

/f' explosi< nor fire. ""V WARNING 1---+--------------+----1 Sign clearly "In maintenance work" and cut off the electricit)l source, before maintenance start. .

Do not ~tart the pump unexpectedly during disassembling or reasserr bling. Sign "Do not put the switch on".

& CAUTION Check t~e leakage of the pump regularly at least once a day.

5. 1 Maintenance

Repair he pump immediately, if an unusual seal leakage occurs.

Since the pump has three rotors engaging with one another with a relath ely small gap in the sleeve, fo eign objects in liquid may bite or flaw the thread or "he bearings. Dry running with some defects may cause seizing in the worst case. Such a f aw

grows to increase the temJ erature at a local spot or to increase an electric current of a motor. In such a casE, disassemble the pump to check the flaw.

12

P 16 / 34

5.2 Periodical maintenance

Maintenance Frequen y Item One ye r Ins{ ection Counter measure

or 8000h Inspects rface of If a rotor itself or a screw

Power Screw and screws ar d rotors for a wears abnormally, and surface to mark or a dent by replace the rotor set. 0 idler contact contact. Measure the rotor bearing outside d. ameter of

rotors. Inspect ir ner surface

Sleeve Inner fora mar , a dent by surface contact or a flaw. 0 Measure nside

diameter of sleeve.

Plain Bearing Inspect hE aring surface If a bearing surface . for a mar , a dent by wears abnormally, 0 bearing surface contact or a flaw; replace the bearing. Inspect tl: e rolling If anything unusual is bearing fc rthe found, replace it with

Roling bearing presence ~f exfoliation new one. 0 and defor rnation. Change gj ease. Inspect s al surface. Replace the mechanical

Mechanical seal seal, if anything 0 abnormal is found.

Packing and Replace the packing or 0 gaskets gasket during overhaul. Inspect a l parts for a If anything unusual is

Shaft coupling flaw and ear. found, replace the 0 coupling.

'

i

13

P 17 / 34

5. 3 Allowance When the dimension of t e rotors, the sleeve, and the bearings is out of the

following allowance, replace he parts with new ones.

EA F 8

-~-r---'/{;11--S lf ,r. ~ - - -A\ - r't-rll f= t--f===:-:>~lr---i _ II+H--t--:""-1-1, ------~70- --: ~ ~

L...----t-'--b_='-.11 """'r~ -------/1- ~- --~~ . .,~ - \LI - vY-Q

I /" ~, l F

1 G

Figure 5. UNIT:m n

POSITION A 8 D E F G

DESIGNDED 62 25 63.5 50 38.1 2C

TOLERANCE + 0.030 + 0.021 + 0.030 / + 0.025 + 0.1 ~21 w 0 0 0 0 0 ....J 0 ALLOWABL ~ :c + 0.060 + 0.042 + 0.060 + 0.050 + 0.1 42 E (Max.) 1- TOLERANCE - 0.079 - 0.040 - 0.072 + 0.012 - 0.030 - 0.1 65 LL

- 0.109 - 0.053 - 0.086 + 0.007 - 0.045 -0. 17 < :c ALLOWABL - 0.218 - 0.106 - 0;172 0 - 0.090 - 0.~ 34 C/) E (Min.)

DESIGN 0.079 0.040 0.072 ~ 0.030 0.065 CLEARANCE - 0.139 -

0.074 -

0.116 - 0.070 - 0. 38

PUMP TYPE : GH-RlT-214, GH-RlT-H 8

14

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6. Causes of trouble and cc untermeasures

Trouble Cause Countermeasure Defective 1. Installed mproperly. 1 .Realign the pump and the motor

S' rotation 2 .Rotors bit ~ foreign objects. 2 .Remove foreign objects and clear the inside of the pump. ;::$ 3 .Assemble( improperly. 3 .Reassemble the pump. p.

..... Sudden stop 1. Rotors hi e foreign objects. 1 .Repair a minl)r flaw: If a flaw is 1 arge, 0 s:l during replace the damaged part. 0

.o operation 2 .Seized or leformed by heat. 2 .Repair or replace the damaged p rt. tH where air is taken in. 3 .Increase o leakage in the 3 .Measure the dimensions of screw ,a

pump sleeve and bearings. If wearing iE over the limit, replace the parts. Confirm that the viscosity of the liquid meets the specification.

Abnormal vibration 1 .Motor 1 .Inspect the motor to see if it is and noise overloaded.

2 .Shaft coup ing 2 .Inspect the alignment of the shaft coupling. Inspect the wearing.

3 .Wear ofpo wer and idler 3 .Measure the dimensions of the rotors parts. If the wearing is over tt. e

limit, replace the parts. 4 .Foreign ob 'ects bite 4 .Repair or replace. 5 .Relief valv ~ is hunting. 5 .Check the parts of the valves. If t ere

is excessive gap, replace them. 6 .Cavitation 6 .Refer to the item [Cavitation] abo V'e. 7 .Others 7 .Inspect the foundation and the pi ing

to see if vibration and noise come from them.

Fluctuations of 1 .Cavitation 1 .Refer to the item [Cavitation] abo e. pressure 2 .Relief valv is hunting. 2 .Adjust set pressure till the relief

valve stops hunting. 3 .Air in pipii g 3 .Adjust an air. ventilation valve. 4 .Others 4 .Inspect whether the fluctuations cf

pressure are affected by other pa r s. Leakage 1 .Seal is fitte d improperly. 1 .Disassemble and reassemble the

pump 2 .Seal wears excessively. 2 .Replace the seal with a new one.

15

P 19 / 34

7. Disassembling and reas ~embling

Understan the content of the instruction manual thoroughly before any ~ork. Take the p oper method and use the proper tools. Replace the used parts N"ith the new parts made by the original suppliers.

Cut off the witch of heat source to decrease temperature to the

CAUTION normalleve 1 before inspection or maintenance.

Depressuri2 e the pump and the piping to ~he atmosphere level and confirm the pressure before disassembling.

Disassembl 3 or reassemble the equipment by licensed or authorized personnel with sufficient knowledge. Fix hanging wire to the ~eavy weight equipment after studying the gravity

l center and he weight.

6 NOTICE Dispose a p ~mp casing, an attachment valve, an exchange part, oil and fat a s the general industry rejection The following points are impo iant for the safety during disassembling the pump.

1. Cut off electricity suppl y. 2. Confirm the teinperatu e of pump casing to be the normal temperature. 3. Prepare a chain or a ch 1in block for lift and a container to collect liquid in the

pump. 4. Do not damage mechan cal sea~. 5. Do not damage surface pf rotating parts such as a power rotor, idler rotors,

bearings, etc.

7. 1 Disassembling( see SECTI PNAL ASSEMBLY) (1) Close the valves on t ~e suction side and the discharge side to cut off t P,e

liquid supply. irom the pump. (When the motor is re~oved from t (2) Disconnect the piping 1e

common bed, the pump an be disassembled with the piping connected.) (3) Remove the pump and or the motor from the common bed. (4) Draw out the shaft co 11pling and the key(103) from the power rotor(101) JY

using tool such as a gea puller or the like. (5) Remove the seal cover(5 J8) and take out the oil seal. (6) Remove the cover(521) and take out the mechanical seal(520) and the b~ 11

bearing(540).

(7) Remove the casing cov ~r(002) by screwing the jack bolts into the casing cov ~r evenly.

(8) Take out the power rot pr(101) and idler rotors(121) together. (9) Remove the rear cover 004). Take out the bearing seat(255) by turning to t e

opposite direction of the pump rotation.

Do not remove the sleeve(2 H) unless it is replace with a new one.

16

P 20 / 34

7. 2 Reassembling (See a~~

P 21 / 34

1-' 00

GHS02!55fi2\IGHSU.:l45:l1>

103) (538) (520) (524) (521) (522 (202' 121 101) (001

,/

532) (543) (54 2) rs..:o

~ I ( I I I I

I

------------- -

---------------------

------------~--------------~= :::-::::-:::-:: :~-::::.:: ::.::::;:, :: ;:,={1: :t: :-:::: ~~~[!:~---'i'l.r---------------------------

orL TANK

I ,, l

I

I -j---r,

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~

~

0048

t--t-

I BIBLIOGRAPHY

~ 5388 5218 0048 0028 543 542 540 538 532 524 522 521 520 257 256 255 202 121 .103 101 071 070 032 0::11 004 002 001 REF. No.

Mechanical Seol ALLOWABLE LEAKAGE ' 3mllh MAKER : PILLAR TYPE : MC3-DF40

Hexagon Heod Boll Corban Steel SS400 Hexagon Heod Boll Carbon Steel SS400 Hexagon Heed Boll Carbon Steel SS400 Hexagon Heed Boll Carbon Steel SS400 Bearing Nut Carbon Steel SS400 Bearing Washer Carbon Steel SS400 Boll Bearing Beorino Steel SUJ2 Seal Cover Carbon Steel SS400 Oil Seal Rubber NBR Spring Seal Carbon Steel SS400 0 Ring Rubber NBR cover Carbon Steel SS400 Mechanical Seal Thrust s .. oi Phosphor Bronze I PBC2 Batonce Piston Bearing Sleel I SUJ2 Bearing Seal Pho_~r Bronze I P8C2 Throat Bush L@oded Bronze I LBC2 Idler Rotor flu:tile ~on I FCD55 Key Carbon Steel I S45C Power Rotor Carbon Steel I S45C o Ring Rubbr I NBR Orcin' Tube Carbon Steel I SS400 o Ring Rubt>r INBR 0 Ring Rubber NBR Rear Cover Carbon Steel I SS400

~ ll. ll. .!! 1 1 1 1 1 1 1 1

~ I .?_ 1 ! 2 1 ~ .?_ 1 1 1 1

Casing Cover Carbon Steel I SS400 I 1 Casing Cas! Iron I FC200 I 1

ps G 5502-'61

NAME OF ARTICLES

I NAME I JIS I WORKING I REHARKS MATERIALS No.

~ 1: 111!1 1 APPRO\r,t'~ .. ,~1-MAIN SEAL OIL PUMP CHECK f-*.17/: ..... w-~~~~~~~ /DESIGNIS.Fviii~ l=.:c~l SECTIONAL ISCALE ~ ~ --...... -- ... ASSFMRI V ~ ~

P 22 / 34

......

~

;--

GHS0.355613 tGHS0~914l

103) (538) (520 524) (521 522

~' I~ (/) I I L-

1

I

./ ~

532 543'

5386' ~ ~ 5213 ""qc '! !' ~ 0046 t: ~ ------------~~-------------

----------------------------===-=-~----:-:..--~~-=-=-=-=-=-=-=-=====-=-= '-=--"1---=-::.-=-=---1-~~,______,.... 1--+-~J I I / I I

l ) OIL TANK -r---,, tt--r

I I

I BIBLIOGRAPHY

~ Mechanical Sect

ALLOWABLE LEAKAGE ' 3mllll MAKER , PILLAR TYPE ' MC3-0F40

538B Hexagon Head Ball Carbon Steel SS400I ~ 5218 lii>>QQOO He!ld lr.

"'' ,.,,""

0046 Hexagon Head Boll Carbon Steel SS400 8 0026 Hoxagon Hood Boll Corban Steel SS_400 8 543 Bearing Nut Carbon Steel 55400 1 542 Bearing Washer Carbon Steel S5400 1 540 Boll Bearing Beorino Steel SUJ2 1 538 Seal COver Corban Steel SS400 1 532 Oil Seal Rubber N6R 1 524 Spring Seat Carbon Steel SS400 1 522 0 Ring Rubber N6R 1 521 Cover Carbon Steel SS400 1 520 Mechanical Seal 1 257 Thrust Seat Phosphor Bronze PBC2 2 256 Balance Piston Bearing Steel SUJ2 2 255 Bearil!S_ s~at Phosohor Bronze PBC2 1 202 Throat Bush Leaded Bronze LBC2 1 121 Idler Rotor Ductle Iron FCD55 2 !Js G 5502-'61 _lo~_ ~y ___ ------ --- -~-OJ!l!lO_~~e~-- ~'L

-+-+-----101 Power Rotor Corban Steel S45C 071 0 Ring Rubber NBR 2 070 DrcinTube Corban Steel SS400 1 032 0 Ring Rubber NBR 1 031 0 Ring Rubber NBR 1 004 Rear Cover Carbon Steel 55400 1 002 Casing Cover Carbon Steel SS400 1 001 Casing Cost Iron FCZO!: 1

. REF. NAME OF NAME JIS WORKING I REMARKS No. ARTICLES MATERIALS No.

!ill~ :lil!l~ APPROVE~'~'""':MERGENCY SEAL OIL PUMP CHECK , :o~'

P 23 / 34

----~~-~~~---- ---- --------"--

1:...:> 0

lll161!f9MOo

IJ,"J'

v ..;

:1-- f ").~~-~

rrtt\11\ ~

2XM10 MOTOR SIDE

ITEM SPEC .f-o EQUIPMENT'S MAIN SEAL z 1/AME OIL PUMP 111 7.5 kW. ~ MDIDR IP.. SPEED 1450 min-1 ;) IURQUE 49.4 Nm 0 111

MAKER I DAIOO-PRECIS!ON INOUSTRIES,LID. NAUE fORIHLEX I COUPUNG

1"--

H s. ~ _;~~t----- --------------------+H-ir---t-~1~ \j ! ~ ~

-~I ! I,J ~ (D)~5 ~

11.2 .I(Gl 140 50

223.5

B WASHER2 I.TEM SPEC 7 WASHER!

Re!cCrd of Chango:s I ~ tDi'71 I 2 Chcg= &,1JUN.22.200

r,"J'

"

~ -;?7

0 0

Al>IIICORROSION COli

1.THE DISTANCE BETWEEN FLANGE 5 BOL't B SCM435 FACES SHALL BE ADJUSTED 4 E!.BMENT 2 SUSSD4

WITHIN 0.25mm /G 3 SPACER l S45G 2 HUB 2 I B45C

2.SPHERICAL FACES OF THIN & 1 HUB I l S45C THICK WASHERS SHALL BE ..... ...... A ~etru;iptlan _ .... d M.:sterio1 rra _ II II FACED TO THE ELEMENTS. eu..stcmr"u Ndr'J6

co N KOSAKA lABORATORY LID. 3.FASTEN THE BOLTS PROPER 0 co co It) TORQUE WITH TORQUE WRENCH 1.1") It) & (") ~ TOSHIBA/ XIT03/04 PROPER TORQUE: 22 Nm I .~ ... ~ C'? . nr:. "'LlJ" I'UIJ Mf' DC. _"'=:!J U.. U..

!!;n-F DURABLE 10 TIMES IN USE. I !XIDE YCAB201567

1116 Dai4B Precision lndustrles Ltd.

MB X 1.0

l~rl . --Renrrks ~ame~

FORM-FLEX COUPUNGS AB-20-P~-42KP/3BKP

-140.

~ .. ~-b~/~ :k:li!!I~'MI!S!flli;;;!:~:M:

P 24 / 34

!>:) ,_..

IIAI.[

NOTE~SEMBUNGINSTRUCTIONS UllE DISTANCE BETWEEN FlANGE FACES SHALL BE ADJUSTED

Wf"IN 0.25mm /G

,-,---, 0 r =-ri'' 8 'i:l

2 0

U'1

~ 0 H t""' 'i:l

~

2.SPHERICAL FACES OF THIN &: ! ! ! . ! .. -- . I . I --- I I I THICK WASHERS SHALL BE J!lt. ~a;-rptiOri i!'l:i ~..... "!!'~.!~~ - RI11CII'kii FACED TO THE ELEMENTS.

P 25 / 34

FL XIBLE DISK COUPLING IN TRUCTION MANUAL

recision n ustr1es FFICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME TOSHI A-KU, TOKYO JAPAN 171-0021

FAX: 81-3-5956-9177

P 26 / 34

This manual details the align ent and assembly of type AX, A4, AB, AS anq A6 4-bolt couplings. Reasonable care in initial assembly and alignment will ssure couplings operate at full c pacity, compensate for misalignment, and p ovide unlimited service life.

1. Coupling Alignment (1) Inspect shafts and hub bores and ensure they are free from burrs or defec s. (2) Check for proper fit of key to shafts and hubs .. (3) After hubs are bored for i terference fit, they should be heated in oil at 90- 20 C

and then quickly installe on the shaft. Do not spot heat as this may ause distortion.

CAUTION: GLOVES SHO LD BE WORN DURING THIS INSTALLATION PROCEDURE.

(4) Insert the shaft in the hub so that shaft end is aligned with the end plane f the hub. (Fig. 1)

(5) Flg.1

Driver and equipment m st be installed in the proper position. The dis ance between flanges should b set within the allowable range of 0.5 mm.

(6) Angular Misalignment (Fig. 2) (a) Install a dial gauge on ne hub as shown in Fig. 2, rotate the same hub, note

the minimum indication f the dial gauge, and set gauge to zero . . (b) Rotate the coupling on which the dial gauge is installed, 360 and djust

position of the connect d equipment until the indicator reading is within 0.05; mm.

recision Industries Ltd. HEAD FFICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKt:rnO 3-CHOME TOSHI -KU; TOKYO JAPAN 171-0021 .

PHONE: 81-3-5 56-9176 FAX: 81-3-5956-9177

l

P 27 / 34

I

Fig.2 (7) Parallel Misalignment (Fig. 3)

(a) Install the dial gauge on the driving side hub and check for p rallel misalignment (Fig. 3). Rotate the coupling on which the dial gauge is installed, 360 and a just height of the connected equipment until. the indicator reading is with n 0.1 mm.

(b) Recheck angular misa ignment and paralell misalignment and ensur they does not exceed the all wable misalignment.

I

Fig. 3

2. Assembly Flexible disk couplings are assembled by various methods (the relation betwee the assembly location of bolts and reamer holes). Each coupling is designed to be fee of defects from the viewpoint of st ength and performance irrespective of whether bolts are tightened from the hub or sp cer side. However, two bolts are tightened from both the hub and spacer side, respec ively on the individual flange planes in principle. Be

/lJl Daido recision Industries Ltd. HEAD FFICE & SALES OFFICE

S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME TOS -KU, TOKYO JAPAN 171-0021

PHONE: 81-3-5 56-9176 FAX: 81-3-5956-9177

2

P 28 / 34

careful not to force these bolts rom the spacer side since bolts cannot be ins rted easily from the spacer side. Als the coupling flanges cannot always be disasse bled due to interference of bolts, if the inter-axis size (D) is smaller than specified in T In such case, insert all bolts fro the hub side while observing the following ass procedure.

CAUTION: AS THESE CO PLINGS USE NYLON NUTS WHICH CANNO BE USED FOR DISASSEMBLY AN ASSEMBLY MORE THAN 10 TIMES, REP ACE NUTS AS REQUIRED.

2.1 When the inter-shaft size is arger than specified in Table 1; Insert two bolts through relief hoi son both hub and spacer sides, respectively.

Table 1 Size D (mm) Size D (mm) 05 65 30 127 10 70 35 142 15 86 40 162 20 95 . 45 176 25 113 50 199

55 246

(1) Install thick washer (2) on ach bolt with its curved surface facing the thre d so that the curved surface tau hes the element to be assembled later.

(2) Assemble the element by inserting two bolts into the relief holes of hu A. Install thin washer (1) on e ch of. these bolts with is curved surface touchin the element, and install the w sher on the bolt threads slightly protruding fro the element surface. (Fig. 4)

Flg.4

g}l Daido recision Industries Ltd. HEAD 0 FICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO T BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME TOSHI -KU, TOKYO JAPAN 171-0021

PHONE: 81-3-59 6-9176 FAX: 81-3-5956-9177

3

P 29 / 34

(3) Insert bolts into the relief ales of hub B, and assemble the element by th same procedure as described i (2), and then, install washers (1).

(4} Install the spacer betwee hubs A and 8; (Fig. 5)

Fig. 5 (5) Insert the assembled bot s in hubs A and B into the spacer side reamer holes

after aligning them with e ch other. (6} Install nuts on each bolt, nd tighten .them lightly. (Fig. 6)

Fig.6

Now, hubs A, B are temper rily assembled on the same shaft together wi h the spacer. (7) Insert bolts from the relief holes an the spacer side with the washe s (2}

previously installed, install thin washer (1) on each between the element an hub with its curved surface t uching the ele.ment after these bolts have p ssed through the element. (Fig. 7)

1/Jl Daido Precision Industries Ltd. HEAD FFICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME TOSH -KU, TOKYO JAPAN 171-0021

PHONE: 81-3-5 56-9176 FAX: 8135956-9177

4

P 30 / 34

Fig. 7

(8) Install nuts from the hub side, and tighten them lightly. (9) After the above assembly tighten the installed bolts at diagonal positions venly

and alternately. Ensure hat the tightening torque of all bolts meets the alues specified in Table 2. No , assembly is completed.

CAUTION : CHECK AND RE DJUST THE DECLJNA TION, MISALIGNMENT, AND TIGHTENING TORQUE OF C UPLING BOLTS, ONE OR TWO HOURS A ER STARTING OPERATION TOP OLONG COUPLING LIFE.

Table 2

Size 05 10 15 20 25 30 35 40 Width across flats 10 10 13 13 17 19 19 24 of bolt head (mm) Fastening torque 9 9 22 22 41 72 72 160 (N-m)

2.2 When the inter-shaft size D is smaller than specified in Table 1; Insert all bolts from the hub side.

45 50 55

24 27 36

160 220 570

(1) Insert two bolts into hub . reamer holes. Install thin washer (1) on eac bolt with its curved surface fac ng the threads so that the curved surface touch s the element to be assembl d later, and then, assemble the element It is recommended to install e ch bolt into the element while turning it, and th bolt can be inserted correctly long its threads. Push the bolts through the hu until the threads slightly protru e from the element surface. (Fig. 8)

UJb Daido recision Industries Ltd. HEAD FFICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME TOSH -KU, TOKYO JAPAN 171-0021

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5

P 31 / 34

Fig. 8

(2) Insert each bolt into hu 8 reamer hole, and assemble thin washer (1) and element in the same way s described in (1 ).

recision Industries Ltd. FFICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME TOSHI -KU, TOKYO JAPAN 171-0021

PHONE: 81-3-5 56-9176 FAX: 81-3-5956-9177

6

P 32 / 34

(3) Install the spacer betwee hubs A and B. (Fig. 9) Hub

---t-1-+H-t- 8

(4) After aligning the bolts as embled on hub A with the relief holes of the s insert bolts toward the sp cer side.

(5) Install thick washer (2) on each hub A bolt from the spacer side with its c rved surface touching the elem nt, and tighten it lightly with the nut. (Fig. 1 0)

(6) Insert the bolts assemble on hub B into the relief holes of the spacer in the same way as described in (4).

(7) Install thick washer (2) fro the spacer side onto each of hub B bolts, and install nuts in the same way as d scribed in (5).

.-

Fig.10 Now, hubs A and B are temporarily assembled on the same shaft togethe with the spacer.

(8) Install thick washer (2) on each of all residual bolts with its curved surface touching the element, and insert the element from the relief hole of the hub

(9) Install thin washer (1) b tween the element and the spacer with its c rved surface touching the elem nt on each bolt. (Fig. 11)

UlJ Daido recision Industries Ltd. FFICE & SALES OFFICE

S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME TOS -KU, TOKYO JAPAN 171-0021

PHONE: 81-3-5956-9176 FAX: 813~5956-9177

7

P 33 / 34

Fig.11 (1 0) Install nuts from the spa er side, and tighten them lightly. (11) After the above assem ly, tighten the bolts installed at diagnonal positions

evenly and alternately. nsure thatthe tightening torque of all bolts mee s the values specified in Table 2. Now, assembly is completed.

CAUTION : CHECK AND RE DJUST THE DECLINATION, MISALIGNMENT, AND TIGHTENING TORQUE OF C UPLING BOLTS ONE OR TWO HOURS A ER STARTING OPERATION TO PR LONG COUPLING LIFE.

recision Industries Ltd. FFICE & SALES OFFICE

3FL. NISHIIKEBUKURO TS BUILDING, 1-15 NISHHKE:BUKURO 3-CHOME TOSHI -KU, TOKYO JAPAN 171-0021

PHONE: 81359 6-9176 FAX: 8135956-9177

8

P 34 / 34

TOSHIBA * ~ :It E KCO 03085-a El REVISAL RECORD

33 FINAL ~ -~~ft13 ~!l!fii pfi .& {tp;j ~ *i~ .... ~:lt ~g~ REV. REV. ISSUED

............................

PAGE CH NGED PLACE AND CONTENT APPROVED BY REVIEWED ~y PREPARED BY

>er. -7 -~o H-~~ ~ ~ fjlt1~J..' a - Initial Issue ~p.-q '1o ~.-8~ vo se,,-J- ~Q I