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7350 E. Progress Place Englewood, CO USA 80111 Toll Free: 800.525.9930 Phone: 303.779.1777 Fax: 303.779.1277A2739 rev B

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MODEL A7 WITH MECHANICAL SEAL

Installation, Operation, Maintenance and Storage Manual

VISIT US AT

WWW.WILFLEY.COM


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TABLE OF CONTENTS

FOREWORD......................................................... 1

1.0 INTRODUCTION ............................................ 2

2.0 SAFETY CONSIDERATIONS ........................ 2

2.1SAFETYTIPS ................................................. 3Apparel ......................................................... 3Maintenance ................................................. 3

3.0 GENERAL INFORMATION ............................ 3

3.1STORAGEREQUIREMENTS ........................ 3

Long-Term Storage ...................................... 4Pump Storage .............................................. 4Parts Storage ............................................... 4Motor and Seal Storage ............................... 4

3.2HANDLING ..................................................... 4

4.0 INSTALLATION .............................................. 5

Inspection upon Arrival ................................ 5Choosing Pump Location ............................. 5Foundation ................................................... 5Alignment ..................................................... 5Piping ........................................................... 6Discharge Piping .......................................... 6Suction Piping .............................................. 6Auxiliary Piping Purge Piping .................... 6Piping Note ................................................... 6

4.1FACTORYPRELIMINARYALIGNMENTPROCEDURE ................................................ 6

4.2RECOMMENDEDPROCEDUREFORBASEPLATEINSTALLATIONANDFINAL

FIELDALIGNMENT ....................................... 6New Grouted Baseplates ............................. 6Alignment Procedure.................................... 7Alignment Checks ........................................ 7Alignment Criteria ......................................... 7Dual-Dial Indicator Alignment Setup ............ 7Angular Alignment ........................................ 8Parallel Alignment ........................................ 8Complete Alignment ..................................... 9Laser Alignment ........................................... 9Alignment Troubleshooting ........................ 10Existing Grouted Baseplates ...................... 10

4.3PIPINGCONNECTION

SUCTION/DISCHARGE ............................... 10Suction Piping ............................................ 10Discharge Piping ........................................ 11Pump and Shaft Alignment Check ............. 11

4.4DRYLOCKISEAL ....................................... 11

4.5MECHANICALSEAL .................................... 11

4.6COUPLING ................................................... 11

4.7COUPLINGGUARD ..................................... 11

5.0 OPERATION ................................................. 11

5.1ROTATIONCHECK ...................................... 11

5.2PRE START-UPCHECKS ............................ 12Starting ....................................................... 12

5.3START-UPCONSIDERATIONS ................... 12

Ensuring Proper NPSHA ............................ 12Minimum Flow ............................................ 13

5.4STARTINGTHEPUMPANDADJ USTINGFLOW ........................................................... 13

5.5THERMALSHOCKINSTRUCTIONS ........... 14

5.6OPERATIONINSUB-FREEZINGCONDITIONS ............................................... 14

5.7SHUTDOWNCONSIDERATIONS ................ 14

6.0 PREVENTIVE MAINTENANCE .................... 14

6.1GENERALSERVICING ................................ 14

Motor .......................................................... 14

6.2PERIODICSERVICING ................................ 14

Need for Maintenance Records ................. 15Need for Cleanliness .................................. 15

6.3MAINTENANCETROUBLESHOOTING ....... 15

7.0 A7 WITH MECHANICAL SEALDISASSEMBLY & REASSEMBLY ............... 19

7.1DISASSEMBLY ............................................. 20

Replacing the Bearings .............................. 20

7.2CLEANING/INSPECTION ............................. 217.3CRITICALMEASUREMENTANDTOLERANCES ............................................. 21

Shaft ........................................................... 21

7.4ASSEMBLY ................................................... 22

Impeller Clearance ..................................... 26Standard A7 Pump ..................................... 26Dial Indicator Procedures ........................... 26Feeler Gauge Procedures .......................... 26

7.5ASSEMBLYTROUBLESHOOTING.............. 27

Reinstallation .............................................. 27

7.6MECHANICALSEALTROUBLESHOOTING

...................................................................... 288.0 LUBRICATION .............................................. 29

Bearing Lubrication .................................... 29

9.0 ORDERING PARTS ..................................... 29

10.0 SPECIAL SERVICE .................................... 30


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FIGURES

Figure 1 Bare Pump Lifting .............................................................................................................................. 4Figure 2 Complete Pump Assembly Lifting ..................................................................................................... 5Figure 3 Pump and Baseplate Lifting .............................................................................................................. 5

Figure 4 Alignment Two-Dial Indicator Method ............................................................................................ 8Figure 5 Pump with Rotation Direction Arrow................................................................................................ 12Figure 6 - A7 Pump with Mechanical Seal ........................................................................................................ 19Figure 7 A7 Frame Assembly ........................................................................................................................ 22Figure 8 A7 Shaft Assembly Step 1 ............................................................................................................... 23Figure 9 A7 Shaft Assembly Step 2 ............................................................................................................... 24Figure 10 A7 Shaft Assembly Step 3 ............................................................................................................. 24Figure 11 A7 Complete Pump Assembly ....................................................................................................... 25Figure 12 Dial Indicator Method (Preferred Method) ..................................................................................... 26Figure 13 Feeler Gauge Method ................................................................................................................... 26Figure 14 Shaft Wrench Drawing .................................................................................................................. 31

TABLES

Table 1 Vertical Cold Settings Values ............................................................................................................. 7Table 2 Alignment Troubleshooting ............................................................................................................... 10Table 3 General Recommendations for Minimum Continuous Flow ............................................................. 13Table 4 Recommended Service Checks ....................................................................................................... 15Table 5 Maintenance Troubleshooting .......................................................................................................... 16Table 6 Casing and Impeller Clearances ...................................................................................................... 26Table 7 Assembly Troubleshooting ............................................................................................................... 27Table 8 Mechanical Seal Troubleshooting .................................................................................................... 28Table 8 Acceptable Oils ................................................................................................................................. 29Table 9 Lubricating Oil Requirements ........................................................................................................... 29Table 10 Approximate Oil Volumes ............................................................................................................... 29Table 11 A7 Nominal Shaft Diameters .......................................................................................................... 31

Table 12 A7 Bolt Torque Values .................................................................................................................... 32


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FOREWORD

This manual provides instructions for the installation, operation, maintenance and storage of the WilfleyModel A7 ANSI Standard Pump. This manual covers the standard product plus common options that areavailable. For special options, supplemental instructions are supplied. This manual must be read andunderstood before installation and start-up.

The design, materials and workmanship incorporated in the construction of Wilfley pumps makes themcapable of giving trouble-free service if properly applied and maintained. The life and satisfactory service ofany mechanical unit is enhanced and extended by correct application, proper installation, periodic inspection,condition monitoring and careful maintenance. This instruction manual was prepared to assist operators inunderstanding the construction and the correct methods of installing, operating, maintaining and storingthese pumps.

A.R. Wil fley and Sons, Inc . shall not be liable fo r damage or delays caused by a fai lu re to observethe instruct ions for installation, operation, maintenance and storage that are contained in thismanual.

Warranty is v alid only when genuine Wilfley parts are used. Contact your local Wilfley

representative for basic warranty info rmation and before making any changes.

Use of the equipment on a service other than stated in the order could nullify the warranty, unless writtenapproval is obtained in advance from A.R. Wilfley and Sons, Inc.

To assure proper installation, supervision from an authorized manufacturers representative isrecommended.

Additional manuals can be obtained by contacting your local Wilfley representative.

THIS MANUAL EXPLAINS

Proper Storage

Proper Installation

Start-up Procedures

Operating Procedures

Preventive Maintenance

Pump Overhaul

Troubleshooting

Ordering Spares or Repair Parts


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1.0 INTRODUCTION

This manual contains instructions and guidelinesfor the installation, operation, maintenance andstorage of the Wilfley A7 ANSI Standard Pump.

There are many factors affecting the successfulinstallation, operation and maintenance of apump. From one pump to the next there istypically significant variation in these factors. Thismakes it impossible to create a bulletin thatcovers all situations.

Therefore, the information contained herein ismeant to serve only as a general guideline. Ifdetailed questions or problems arise, contact theWilfley Sales Office or authorizedDistributor/Representative.

It is extremely important that this entiremanual be read prior to installation or start-upof the pump.

This is important for safety, for properperformance of the pump and for maximum Mean

Time between Planned Maintenance (MTBPM).

2.0 SAFETY CONSIDERATIONS

Like all machinery, centrifugal pumps can bedangerous if used improperly. Any of the followingmisuses may result in a pump that does not

function properly. A pump that does not functionproperly may be a hazard and could causedamage or injury.

For maximum safety and reliability, use onlyfactory-supplied parts and closely follow allmaintenance and operating recommendations andinstructions.

Do not change the pumping conditions orinstallations of a Wilfley pump without consultingA.R. Wilfley and Sons, Inc. first to ascertain if thepump is capable of handling the new conditionsand/or fluid. It is not possible to list all theconceivable misuses. Therefore, the following listis not meant to be complete and is provided onlyas a guide ofthe types of misuse that candamage a pump and cause injury. The list willalso give a good idea of the kinds of misuses thatwill void any and all warranties.

1. Do not run a pump with the discharge valveclosed or below minimum rated flow.

2. Do not run a pump in the reverse direction.

3. Do not start a pump that is wind-milling inthe reserve direction due to fluid flowingback down the discharge pipe.

4. Do not continue to operate a pump whenthere are indications that something isrubbing, binding or knocking.

5. Do not continue to run a pump that gives anindication of overheating.

6. Do not operate a pump with the couplingguard removed. Make sure the guard fitssnugly around the coupling so there are noopenings.

7. Do not operate a pump that is excessivelyvibrating, surging or making abnormalnoise.

8. Do not work on a pump unless the drivesystem is locked out and the pump isdisconnected from the drive system.

9. Do not connect the pump to the drivesystem without first checking to see that thedrive system is running in the correctdirection.

10. Do not rely on the factorys alignment of thepump and the drive system. Alignment mayhave changed during shipment.

11. Do not put a cold liquid in or on a hot pumpor a hot liquid in or on a cold pump.

12. Do not hit a pump with any object.

13. Do not use worn or faulty parts.

14. Do not stick hands, arms, legs or any otherobject into the discharge, suction or anyother opening of a pump.

15. Do not weld attachments to the pump.

16. Do not apply external heat to the pump.

17. Do not lift the pump by its case only.

18. Do not examine a pump without usingproper eye and face protection.

19. Do not run equipment dry or start the pumpwithout the proper prime (Casing Flooded).

20. Do not exceed the maximum allowablepressure (Max. P. @ 38

C as shown on

pump nameplate).


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The Wilfley A7 process pump has been designedand manufactured for safe operation. In order toensure safe operation, it is very important that thismanual be read in its entirety prior to installing oroperating the pump. Wilfley shall not be liable forphysical injury, damage or delays caused by afailure to observe the instructions for installation,operation and maintenance contained in thismanual.

Remember that every pump has the potential tobe dangerous, because of the following factors:

Parts are rotating at high speeds.

High pressures may be present.

High temperatures may be present.

Highly corrosive and/or toxic chemicals maybe present.

Paying constant attention to safety is alwaysextremely important. However, there are oftensituations that require special attention. Thesesituations are indicated throughout this book bythe following symbols:

DANGER Immediate hazards that WILL result in

severe personal injury or death.

WARNING Hazards or unsafe practices thatCOULD result in severe personal injury or death.

CAUTION - Hazards or unsafe practices thatCOULD result in minor personal injury or productor property damage.

NOTE: ALWAYS COORDINATE REPAIRACTIVITY WITH OPERATIONS PERSONNELAND FOLLOW ALL PL ANT SAFETYREQUIREMENTS AND APPLICABLE SAFETYAND HEALTH LAWS/REGULATIONS.

2.1 SAFETY TIPS

Apparel

Insulated work gloves when handling hotbearings or using bearing heater

Heavy work gloves when handling partswith sharp edges, especially impellers

Safety glasses (with side shields) for eyeprotection, especially in machine shopareas

Steel-toed shoes for protection whenhandling parts, heavy tools, etc.

Other personal protective equipment toprotect against hazardous/toxic fluids

Maintenance

Always lockout/tagout power.

Ensure pump is isolated from system andpressure is relieved before disassemblingpump, removing plugs, or disconnectingpiping.

Use proper lifting and supporting equipmentto prevent serious injury.

Observe proper decontaminationprocedures.

Know and follow company safetyregulations.

Never apply heat to remove impeller.

Observe all cautions and warningshighlighted in pump instruction manual.

3.0 GENERAL INFORMATION

3.1 STORAGE REQUIREMENTS

If the pump is inoperative for a long period of time,it is recommended that the pump be flushed andthoroughly dried to minimize corrosion. It is alsoadvisable to drain the lines and case if there is apossibility of freezing. If the pump is to be storedfor more than 15 days, the pump should berotated once a week to lubricate and to preventrusting of the bearings.

DANGER!

WARNING!

CAUTION!


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Long-Term Storage

The following guidelines should be followed whenthe pump or parts will be idle for a period of onemonth or more.

Pump Storage

1. All machined metal surfaces should becoated with a suitable corrosion inhibitor toensure the integrity of these surfaces at thetime of installation.

2. All openings must be covered with suitablecovers to protect against contaminants.

3. Storage of the Components and Assembliesshould be kept away from all potentialvibration sources. (i.e., motors, rotating

pumps, engines, etc.). This is to preventunwanted vibration and possible brinellingof the bearings.

4. Components and assemblies are requiredto be stored indoors in a dry location.

Temperature range should be between 40degrees and 100 degrees Fahrenheit. If theenvironment is excessively humid (morethan 70%), a suitable desiccant should beused.

5. Pump shafts are required to be rotated 5 fullrevolutions weekly to prevent brinelling.

Parts Storage

Not all parts are packaged in a suitable mannerfrom the factory for long-term storage. To ensuresatisfactory part performance, all parts must beprotected from corrosion and contamination.

Motor and Seal Storage

Refer to the manufacturers manuals for storageinstructions for these items.

3.2 HANDLING

The following describes how to lift pumpcomponents, assembled pumps, or pump, motorand baseplate assemblies. Do not attempt to lift apump mounted on a baseplate by itself.A pump-motor assembly may only be lifted after ithas been installed on a baseplate. Lifting shouldonly be done by trained personnel. Pumps andmotors often have integral lifting eyes or eye bolts.

These are intended for use in lifting the individualpiece of equipment.

Do not use eyebolts or cast-in lifting lugs to liftpump, motor and baseplate assemblies.

Before lifting the equipment, refer to the pumpdata sheet for the complete assembly weight.

Pump Components:

Casing: Use a choker hitch pulled tight around thedischarge nozzle.Bearing frame: Insert a sling between the upperand lower support ribs between the housing barreland the casing attachment flange. Use a chokerhitch when slinging. Caution: make sure there areno sharp edges on the bottom side of the ribs thatcould cut the sling.

Bare Pump:

Sling around the pump discharge nozzle andaround the outboard end of the bearing housingwith separate slings. Choker hitches must be usedat both attachment points and pulled tight. Makesure the completion of the choker hitch on thedischarge nozzle is toward the coupling end of thepump shaft as shown in Figure 1. The slinglengths should be adjusted to balance the loadbefore attaching the lifting hook.

Figure 1 Bare Pump Li fting

CAUTION!


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Pump, motor and steel baseplateassembly:

Insert lifting S hooks in the lifting lugs and useslings or chains to connect to the lifting eye asshown in Figure 2. Do not use slings through the

lifting holes.

Figure 2 Complete Pump Assembly Lif ting

Pump, motor and cast iron ornonmetallic baseplate assembly:

Nonmetallic baseplates can easily be damaged inhandling. Be careful to handle the baseplategently and avoid any shocks. This assemblyutilizes a wooden shipping pallet that should beleft intact until final installation. The assemblyshould be forklifted on the pallet to the installationsite and then removed only when ready to be

installed. Sling around the pump discharge nozzleand around the motor-mounting end of thebaseplate as shown in Figure 3. Choker hitchesmust be used at both attachment points andpulled tight. The sling lengths should be adjustedto balance the load before attaching the liftinghook. Do not use slings through any lifting holesand be careful not to damage the baseplatematerial.

Figure 3 Pump and Baseplate Lifting

4.0 INSTALLATION

Inspection upon Arrival

Your pump has been carefully inspected andtested prior to shipment to ensure that it meets

your requirements. Please inspect the pump uponarrival for any damage that may have occurredduring shipment. Report any damage immediatelyto the carrier.Leave all shipping covers attached to the pumpunit until it is ready for installation. If installation isto be delayed more than 15 days, the pump shaftshould be rotated by hand once a week tolubricate the bearings and prevent rusting.

Choosing Pump Location

The following recommendations may be helpful

when choosing the best location for your pump:

1. Locate the pump as close to the liquidsource as practical so the suction pipe isshort and direct with a minimum of elbows,fittings and valves.

2. Place the pump in a location so the unit isaccessible for inspection during operationas well as for maintenance operationsinvolving removal and disassembly.

Foundation

The foundation should be sufficient to absorb anyvibration and to form a permanent, rigid supportfor the baseplate. This is important to maintain thecorrect alignment of the direct connected unit. Aconcrete foundation on a solid base issatisfactory. Foundation bolts of the proper sizeshould be embedded in the concrete located asindicated on the outline drawing.

Al ignment

The pump and motor are aligned at the factory

before shipment. Realignment may be necessaryafter the complete unit has been leveled on thefoundation and after the foundation bolts havebeen tightened. Procedures for checking andaligning the pump components are in section 4.2of this manual and may also be found in theHydraulic Institute Standards.


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Piping

Both suction and discharge pipes should besupported independently near the pump so whenthe flange bolts are tightened no strain will betransmitted to the pump casing. The customer is

responsible for proper suction and discharge pipedesign and layout to avoid flow induced problems.

Discharge Piping

A valve should be installed in the discharge line toprevent fluid from flowing back through the pumpwhen it is shut down. The valve should block thedischarge line during maintenance.

Suction Piping

Care should be taken in sizing and locating

suction piping to prevent cavitation. A valveshould be installed in the suction line to preventfluid from flowing into the pump when it is shutdown.

Auxi liary Piping Purge Piping

When required, purge piping is supplied with thepump. An external connection should be made atthe pump so purge flow can be varied as requiredby valving and the pressure can be monitored.Piping fittings and gauges must be corrosionresistant to the fluid being pumped.

Piping Note

Refer to the Hydraulic Institute Standards forcentrifugal pumps for additional pipinginformation.

4.1 FACTORY PRELIMINARYALIGNMENT PROCEDURE

The pump and motor are aligned at the factory toverify the assembly.

4.2 RECOMMENDEDPROCEDURE FOR BASEPLATEINSTALLATION AND FINALFIELD ALIGNMENT

New Grouted Baseplates

1. The pump foundation should be located asclose to the source of the fluid to bepumped as practical. There should be

adequate space for workers to install,operate and maintain the pump. Thefoundation should be sufficient to absorbany vibration and should provide a rigidsupport for the pump and motor.Recommended mass of a concretefoundation should be three times that of thepump, motor and base.

2. Level the pump baseplate assembly withthe pump and motor on the baseplate. Theproper surfaces to reference when levelingthe pump baseplate assembly are the pumpsuction and discharge flanges. DO NOTstress the baseplate. Do not bolt the suctionor discharge flanges of the pump to thepiping until the baseplate foundation iscompletely installed. If equipped, useleveling jackscrews to level the baseplate. If

jackscrews are not provided, shims and

wedges should be used. Check forlevelness in both the longitudinal and lateraldirections. Shims should be placed at allbase anchor bolt locations and in the middleedge of the base if the base is more thanfive feet long. Do not rely on the bottom ofthe baseplate to be flat. Standard baseplatebottoms are not machined, and it is notlikely that the field-mounting surface is flat.

3. After leveling the baseplate, tighten theanchor bolts. If shims were used, make surethat the baseplate was shimmed near each

anchor bolt before tightening. Failure to dothis may result in twisting of the baseplate,which could make it impossible to obtainfinal alignment. Check the level of thebaseplate to make sure that tightening theanchor bolts did not disturb the level of thebaseplate. If the anchor bolts did changethe level, adjust the jackscrews or shims asneeded to level the baseplate. Continueadjusting the jackscrews or shims andtightening the anchor bolts until thebaseplate is level.

4. Check initial alignment between the pumpand driver with a straight edge and correctas needed.

5. Grout the baseplate. A nonshrinking groutshould be used. Make sure that the groutfills the area under the baseplate. After thegrout has cured, check for voids and repairthem. J ackscrews, shims and wedgesshould be removed from under thebaseplate at this time. If they were to be leftin place, they could rust, swell and causedistortion in the baseplate.


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6. Run piping to the suction and discharge ofthe pump. There should be no piping loadstransmitted to the pump after connection ismade. Recheck the alignment to verify thatthere are no significant loads.

7. Use the following procedure and set up thefinal alignment between the pump anddriver.

Step 8 follows the alignment section.

Al ignment Procedure

Before beginning any alignment procedure makesure driver power is locked out

The points at which alignment is checked andadjusted are:

Initial Alignment is done prior to operationwhen the pump and the driver are atambient temperature.

Final Alignment is done after operationwhen the pump and driver are at operatingtemperature.

Adding or removing shims under the feet of the

motor and pump and by shifting equipmenthorizontally as needed achieves alignment.

NOTE: Proper alignment is the responsibility ofthe installer and user of the unit, not Wilfley.

Accurate alignment of the equipment must beobtained and sustained. Trouble-free operationcan be accomplished by following the properprocedures.

Al ignment Checks

Initial Alignment (Cold Alignment)

Before Grouting Baseplate To ensurealignment can be obtained.

After Grouting Baseplate To ensure nochanges have occurred during the groutprocess.

After Connecting Piping To ensure pipestrains havent altered alignment. If changeshave occurred, alter piping to remove pipestrains on pump flanges.

Final Alignment (Hot Alignment)

After First Run To obtain correctalignment when both pump and driver are atoperating temperature. Thereafter,alignment should be checked periodically inaccordance with plant operatingprocedures.

Al ignment Cri ter ia

Good alignment is achieved when the dialindicator readings are specified in the alignmentprocedure as 002 in (.05 mm) Total Indicated

Reading (T.I.R.) or less when the pump and driverare at operating temperature (Final Alignment).

During the installation phase, however, it isnecessary to set the parallel alignment in thevertical direction to a different criterion due todifferences in expansion rates of the pump anddriver. Recommended preliminary (cold) settingsfor electric motor-driven pumps based on differentpumpage temperatures are listed in the followingtable.

Table 1 Vertical Cold Settings Values

Pumpage Temp Set Driver Shaft

50F (10C) 0.002 in (0.05 mm) LOW

122F (50C) 0.001 in (0.03 mm) HIGH

302F (150C) 0.005 in (0.12 mm) HIGH

Dual-Dial Indicator Alignment Setup

1. Mount two dial indicators on one of thecoupling halves P so they contact the othercoupling halfM.

2. Check setting of indicators by rotatingcoupling halfP to ensure indicators stay in

contact with coupling halfM but do notbottom out. Adjust indicators accordingly.

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Figure 4 Alignment Two-Dial Indicator

Method

Measurement

1. To ensure accuracy of indicator readings,always rotate both coupling halves togetherso indicators contact the same point oncoupling halfM. This will eliminate anymeasurement problems due to runout oncoupling halfM.

2. Take indicator measurements with driverfeet hold-down bolts tightened. Loosenhold-down bolts prior to making alignmentcorrections.

3. Take care not to damage indicators whenmoving driver during alignment corrections.

Angular Alignment

A unit is in angular alignment when indicatorA(Angular Indicator) does not vary by more than

.002 in (.05 mm) as measured at four points 90apart.

Vertical Correction (Top to Bottom)

1. Zero indicatorA at top dead center (12oclock) of coupling halfM.

2. Rotate indicators to bottom dead center (6oclock). Observe needle and recordreading.

3. Negative Reading The coupling halvesare further apart at the bottom than the top.Correct by either raising the driver feet atthe shaft end (add shims) or lowering thedriver feet at the other end (remove shims).Positive Reading The coupling halvesare closer at the bottom than at the top.Correct by either lowering the driver feet at

the shaft end (remove shims) or raising thedriver feet at the other end (add shims).

4. Repeat steps 13 until indicatorA reads.002 in (.05 mm) or less.

Horizontal Correction (Side to Side)1. Zero indicatorA on the left side of coupling

halfM, 90 from top dead center (9 oclock).

2. Rotate indicators through top dead center to

the right side, 180 from the start (3oclock). Observe needle and recordreading.

3. Negative Reading The coupling halvesare further apart on the right side than theleft. Correct by either sliding the shaft end ofthe driver to the left or the other end to theright.Positive Reading The coupling halvesare closer together on the right side thanthe left. Correct by either sliding the shaftend of the driver to the right or the other endto the left.

4. Repeat steps 13 until indicatorA reads.002 in (.05 mm) or less.

5. Re-check both horizontal and verticalreadings to ensure adjustment of one didnot disrupt the other.

Parallel Alignment

A unit is in parallel alignment when indicator B(Parallel Indicator) does not vary by more than

.002 in (.05mm) as measured at four points 90apart at operating temperature. Note thepreliminary vertical cold setting table for values.


1. Zero indicatorB at top dead center ofcoupling (12 oclock) halfM.

2. Rotate indicator to bottom dead center (6oclock). Observe needle and recordreading.

B

A

M P

MOTOR END PUMP END


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3. Negative Reading Coupling halfP islower than coupling halfM. Correct byadding shims of thickness equal to half ofthe indicator reading under each driver foot.Positive Reading Coupling halfP ishigher than coupling halfM. Correct byremoving shims of thickness equal to half ofthe indicator reading from each driver foot.

NOTE: Equal amounts of shims must beadded to or removed from each driverfoot . Otherwise the vertical angularalignment wil l be affected.

4. Repeat steps 13 until indicatorB readswithin .002 in (.05 mm) or less when hot, orper the vertical cold setting table values.

Horizontal Correction (Side to Side)

1. Zero indicatorB on the left side of the

coupling halfM, 90 from top dead center (9oclock).


the right side, 180 from the start (3oclock). Observe needle and recordreading.

3. Negative Reading Coupling halfM is tothe left of coupling halfP. Correct by slidingdriver evenly in the appropriate direction.Positive Reading coupling halfM is tothe right of coupling halfP. Correct bysliding the driver evenly in the appropriatedirection.

NOTE: Failure to slide motor evenly willaffect horizontal angular correction.

4. Repeat steps 13 until indicatorB reads.002 in (.05 mm) or less.

5. Re-check both horizontal and verticalreadings to ensure adjustment of one didnot disrupt the other. Correct as necessary.

Complete Alignment

A unit is in complete alignment when bothindicatorsA (angular) and B (parallel) do not varyby more than 0.002 in (0.05 mm) as measured at

four points 90 apart.

Figure 4 Alignment Two-Dial IndicatorMethod


1. Zero indicatorsA and B at top dead center(12 oclock) of coupling halfM.

2. Rotate indicator to bottom dead center (6oclock). Observe the needles and recordthe readings.

3. Make corrections as outlined previously.

Horizontal Correction (Side to Side)

1. Zero indicatorsA and B on the left side of

coupling halfM, 90 from top dead center (9oclock).


the right side, 180 from the start (3oclock). Observe the needle, measure andrecord the reading.

3. Make corrections as outlined previously.

4. Re-check both vertical and horizontalreadings to ensure adjustment of one didnot disrupt the other. Correct as necessary.

NOTE: With experience, the installer willunderstand the interaction between angularand parallel and will make correctionsappropriately.

Laser Alignment

This method can be used in place of the dual dialindicator method. P lease follow the instructionsgiven by the laser equipment manufacturer.

B

A

M P

MOTOR END PUMP END


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Al ignment Troubleshooting

Operate the pump for at least an hour or until itreaches final operating temperature. Shut thepump down and recheck alignment while thepump is hot. Piping thermal expansion may

change the alignment. Realign pump asnecessary. See table below for possible alignmentissues.

Table 2 Alignment Troubleshooting

PROBLEMPOSSIBLE

CAUSERECOMMENDED

REMEDY

Cantobtainhorizontal(side toside)alignment,angular orparallel.

Driver feetbolt bound.

Loosen pump holddown bolts and slidepump and driver untilhorizontal alignmentis achieved.

Baseplatenot leveledproperly,possiblytwisted.

Determine whichcorner(s) of thebaseplate are high orlow and remove oradd shims at theappropriate corner(s)and realign.

Cantobtainvertical (topto bottom)alignment,angular orparallel.

Baseplatenot leveledproperly,possiblybowed.

Determine if center ofbaseplate should beraised or lowered andcorrect by evenlyadding or removingshims at the center ofthe baseplate.

Existing Grouted Baseplates

When a pump is being installed on an existinggrouted baseplate, the procedure is somewhatdifferent from the previous section New GroutedBaseplates.

1. Mount the pump on the existing baseplate.

2. Level the pump by putting a level on thedischarge flange. If not level, adjust the footpiece by adding or deleting shims betweenthe bearing frame and baseplate.

3. Check initial alignment between the pumpand driver with a straight edge and correctas needed.

4. Run piping to the suction and dischargeflanges of the pump.

5. Perform final alignment.

6. Recheck alignment after pump is hot.

4.3 PIPING CONNECTION SUCTION/DISCHARGE

All piping must be independently supported,accurately aligned and preferably connected tothe pump by a short length of flexible piping. The

pump should not have to support the weight of thepipe or compensate for misalignment. It should bepossible to install suction and discharge boltsthrough mating flanges without pulling or pryingeither of the flanges. All piping must be airtight.Pumps may air-bind if air is allowed to leak intothe piping. If the pump flange(s) have tappedholes, select flange fasteners with threadengagement at least equal to the fastenerdiameter but that do not bottom out in the tappedholes before the joint is tight.

Piping Forces:Take care during installation and operation tominimize pipe forces and/or moments on thepump casing.

Suction Piping

To avoid NPSH and suction problems, suctionpipe sizes must be the same or greater than thepump suction connection. Neveruse pipe or

fittings on the suction that are smaller in diameterthan the pump suction size.

The ideal piping configuration should have aminimum of 10 pipe diameters between thesource and the pump suction. In most cases,horizontal reducers should be eccentric andmounted with the flat side on top or up with amaximum of one pipe size reduction. Never mounteccentric reducers with the flat side down.Horizontally mounted concentric reducers shouldnot be used if there is any possibility of entrainedair in the process fluid. Vertically mountedconcentric reducers are acceptable. In

applications where the fluid is completely de-aerated and free of any vapor or suspendedsolids, concentric reducers are preferable toeccentric reducers.Avoid the use of throttling valves and strainers inthe suction line. Start-up strainers must beremoved shortly after startup. When the pump isinstalled below the source of supply, a valveshould be installed in the suction line to isolate thepump and to permit pump inspection andmaintenance. However, never place a valvedirectly on the suction nozzle of the pump. Referto the Centrifugal Pump IOM Section of the

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Hydraulic Institute Standards for additionalrecommendations on suction piping.

Discharge Piping

Install a valve in the discharge line. This valve is

required for regulating flow and/or to isolate thepump for inspection and maintenance.

A rapidly closing discharge valve can cause adamaging pressure surge. A dampeningarrangement should be provided in the piping.

Pump and Shaft Alignment Check

After connecting piping, rotate the pump driveshaft clockwise (view from motor end) severalcomplete revolutions by hand to be sure there isno binding and that all parts are free. Recheckshaft alignment. If piping caused unit to be out ofalignment, correct piping to relieve strain on thepump.

4.4 DRYLOCK I SEAL

When the pump is intended to be equipped with aDryLock

I seal, it is Wilfleys standard practice to

install the DryLock

I seal in the pump prior to

shipment. Specific order requirements mayspecify that the seal be shipped separately, ornone be supplied. It is the pump installersresponsibility to determine if a seal was installed.If a seal was supplied but not installed, use theseal installation instructions found in section 7.4.

4.5 MECHANICAL SEAL

When the pump is intended to be equipped with amechanical seal, it is Wilfleys standard practice toinstall the mechanical seal in the pump prior to

shipment. Specific order requirements mayspecify that the seal be shipped separately, ornone be supplied. It is the pump installersresponsibility to determine if a seal was installed.If a seal was supplied but not installed, the sealand installation instructions will be shipped withthe pump.

4.6 COUPLING

The coupling should be installed as advised bythe coupling manufacturer. Pumps are shippedwithout the spacer installed. If the spacer hasbeen installed to facilitate alignment, then it must

be removed prior to checking rotation. Removeprotective material from the coupling and anyexposed portions of the shaft before installing thecoupling.

4.7 COUPLING GUARD

Power must neverbe applied to the driver whenthe coupling guard is not installed.

Wilfley coupling guards are safety devicesintended to protect workers from inherent dangersof the rotating pump shaft, motor shaft andcoupling. It is intended to prevent entry of hands,fingers or other body parts into a point of hazardby reaching through, over, under or around theguard. No standard coupling guard providescomplete protection from a disintegratingcoupling. Wilfley cannot guarantee its guards willcompletely contain an exploding coupling.

The Wilfley coupling guard conforms to the U.S.A.standard ASME B15.1, Safety Standard for

Mechanical Power Transmission Apparatus.

5.0 OPERATION

5.1 ROTATION CHECK

A d irect ion ar row is cast on the fron t o f thecasing (See Figure 5). Make sure the motorrotates in the same direction before coupling

the motor to the pump. It is absolutely essentialthat the rotation of the motor be checked beforeconnecting the shaft coupling. Incorrect rotation ofthe pump, for even a short time, can dislodge theimpeller, which may cause serious damage to thepump. All Wilfley Model A7 pumps turn clockwiseas viewed from the motor end, or conversely,counterclockwise when viewed from the suctionend, as shown in Figure 5.

WARNING!

WARNING!

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Figure 5 Pump with Rotation Direction Ar row

5.2 PRE START-UP CHECKS

Prior to starting the pump, it is essential that thefollowing checks be made.

Visually check all main and auxiliary pipingto ensure that all connections have beenproperly made.

Check voltage, fuse, starter amperageratings and frequency on the motornameplate against the electrical supplycharacteristics.

Visually inspect all electrical connections tothe motor and control circuit.

Check the rotation of the motor by

momentarily starting the motor with motordisconnected from the pump assembly.Direction of rotation must be as shown bythe arrow on the pump case and thedirection of rotation plate on the top of theframe. Starting or running pump backwardswill cause damage.

Pump and motor are properly secured tothe baseplate.

All fasteners tightened to the correcttorques.

Coupling guard in place and not rubbing.

Impeller clearance setting.

Bearing lubrication.

Pump instrumentation is operational.

Pump is primed.

As a final step in preparation for operation, it isimportant to rotate the shaft by hand to be certainthat all rotating parts move freely and that thereare no foreign objects in the pump casing.

Starting

Before starting the pump, it is advisable to havethe pump casing and suction line filled with liquid.It is normal to have the discharge valvemomentarily closed when the pump is startedsince much less horsepower is required underthese conditions.

DO NOT OPERATE THE PUMP IN A DEAD-HEAD (NO FLOW) CONDITION.

5.3 START-UPCONSIDERATIONS

Ensuring Proper NPSHA

Net Positive Suction Head Available (NPSHA) isthe measure of the energy in a liquid above thevapor pressure. It is used to determine thelikelihood that a fluid will vaporize in the pump. Itis critical because a centrifugal pump is designedto pump a liquid, not a vapor. Vaporization in apump will result in damage to the pump,deterioration of the Total Differential Head (TDH)and possibly a complete stoppage of pumping.

Net Positive Suction Head Required (NPSHR) isthe decrease of fluid energy between the inlet ofthe pump and the point of lowest pressure in thepump. This decrease occurs because of frictionlosses and fluid accelerations in the inlet region ofthe pump and, particularly, accelerations as thefluid enters the impeller vanes. The value forNPSHR for the specific pump purchased is givenin the pump data sheet and on the pumpperformance curve. For a pump to operateproperly the NPSHA must be greater than theNPSHR. Good practice dictates that this marginshould be at least 3 ft (1 m) or 20%, whichever is

greater.

Ensuring that NPSHA is larger than NPSHR bythe suggested margin will greatly enhance pumpperformance and reliability. It will also reduce thelikelihood of cavitation, which can severelydamage the pump.

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Minimum Flow

Minimum continuous stable flow is the lowest flowat which the pump can operate and still conformto the bearing life, shaft deflection and bearinghousing vibration limits of ANSI/ASME B73.1M-

1991. Pumps may be operated at lower flows, butit must be recognized that the pump may notconform to one or more of these limits and theoperating life may be significantly reduced. Forexample, vibration may exceed the limit set by theASME H.I. 9.6 standard. The size of the pump,the energy absorbed and the liquid pumped aresome of the considerations in determining theminimum flow. See the following table for generalrecommendations. Special conditions, such assolids handling, may significantly raise theserecommendations.

Table 3 General Recommendations forMinimum Continuous Flow

PUMP SIZE/DESIGNATION

% BEP

@ 3550 /2950RPM;

60/50 HZ

@ 1750 /1450RPM;

60/50 HZ

1.5x1-6 AA-6 15 103x1.5-6 AB-6 15 101.5x1-8 AA-8 20 103x1.5-8 A50-8 20 103x2-8 A60-8 20 104x3-8 A70-8 20 10

2x1-10 A05-10 25 103x1.5-10 A50-10 25 103x2-10 A60-10 30 154x3-10 A70-10 30 156x4-10 A80-10 30 15

3x1.5-13 A20-13 30 153x2-13 A30-13 40 154x3-13 A40-13 40 406x4-13 A80-13 - 408x6-15 A110-15 - 5010x8-15 A120-15 - 508x6-16S - 5510x8-16S - 60

All Wilfley A7 pumps also have a MinimumThermal Flow. This is defined as the minimumflow that will not cause an excessive temperaturerise. Minimum Thermal Flow is applicationdependent.

Do not operate the pump at or below MinimumThermal Flow, as this could cause an excessivetemperature rise. Contact a Wilfley SalesEngineer for determination of Minimum ThermalFlow.

5.4 STARTING THE PUMP ANDADJUSTING FLOW

1. Open the suction valve to full open position.It is very important to leave the suctionvalve open while the pump is operating. Anythrottling or adjusting of flow must be donethrough the discharge valve. Partiallyclosing the suction valve can create serious

NPSH and pump performance problems.

Never operate pump with both the suctionand discharge valves closed. This couldcause an explosion.

2. A standard centrifugal pump will not moveliquid unless the pump is primed. A pump issaid to be primed when the casing and the

suction piping are completely filled withliquid. Open discharge valve a slightamount. This will allow any entrapped air toescape and will normally allow the pump toprime, if the suction source is above thepump. When a condition exists where thesuction pressure may drop below thepumps capability, it is advisable to add alow-pressure control device to shut thepump down when the pressure drops belowa predetermined minimum.

3. All cooling, heating and flush lines must bestarted and regulated.

4. Start the driver (typically, the electric motor).

5. Slowly open the discharge valve until thedesired flow is reached, keeping in mind theminimum flow restrictions listed above.

WARNING!

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It is important that the discharge valve beopened within a short interval after startingthe driver. Failure to do this could cause adangerous build up of heat and possibly anexplosion.

6. Reduced CapacityAvoid running a centrifugal pump atdrastically reduced capacities or with thedischarge valve closed for extended periodsof time. This can cause severe temperaturerise and the liquid in the pump may reach itsboiling point. If this occurs at a minimum,the seal may be damaged, as it will beexposed to vapor, will have no lubricationand may score or seize to the stationary

parts. It is also possible that it can create anexplosive condition. If the suction valve isalso closed, there is an even greater risk ofcatastrophic failure such as an explosion.

Thermostats may be used to safeguardagainst over heating by shutting down thepump at a predetermined temperature

Safeguards should also be taken againstpossible operation with a closed dischargevalve, such as installing a bypass back tothe suction source. The size of the bypass

line and the required bypass flow rate is afunction of the input horsepower and theallowable temperature rise.

7. Reduced HeadNote that when discharge head drops, thepumps flow rate usually increases rapidly.Check motor for temperature rise as thismay cause overload. If overloading occurs,throttle the discharge.

8. Surging ConditionA rapidly closing discharge valve can cause

a damaging pressure surge. A dampeningarrangement should be provided in thepiping.

5.5 THERMAL SHOCKINSTRUCTIONS

For thermal shock start-up instructions, pleasecontact the Wilfley factory in Denver.

5.6 OPERATION IN SUB-FREEZING CONDITIONS

When using the pump in sub-freezing conditionswhere the pump is periodically idle, the pumpshould be properly drained or protected withthermal insulating devices which will keep theliquid in the pump from freezing. High-chrome ironpumps are not recommended for applicationsbelow 0F (-18C).

5.7 SHUTDOWN

CONSIDERATIONS

When the pump is being shut down, theprocedure should be the reverse of the start-upprocedure. First, slowly close the discharge valve,shut down the driver and then close the suctionvalve. Remember, closing the suction valve whilethe pump is running is a safety hazard and couldseriously damage the pump and other equipment.

6.0 PREVENTIVE MAINTENANCE

6.1 GENERAL SERVICING

Your Wilfley Model A7 pump is designed toprovide long and trouble-free service with aminimum of maintenance. It is recommended thatthe pump be inspected at regular intervals. It isalso suggested that a service record be kept forthe pump.

Motor

Refer to the motor manufacturers manual forrecommended service instructions. It is

recommended that the motor be well ventilatedwhen in operation.

6.2 PERIODIC SERVICING

The following table contains recommendedservice checks that should be performed on aperiodic basis.

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Table 4 Recommended Service Checks

AfterFirstStart-

Up

EveryWeek

Every6

Months

Flow, Pressure,

Temperature (a)

X X

Visual (b) X X

Noise / Vibration X X

Oil Level X X

Grease Bearings X X

a. Flow, Pressure, Temperature: All flow,pressure and temperature gauges shouldbe monitored to ensure that the pump isoperating within specified limits. If the frametemperatures are monitored, thistemperature generally should not exceed160F (71.1C).

b. Visual: Periodic visual inspection should bemade of the pump and its installation.

This inspection should include the following:

1. All mounting supports should be secure.

2. All external nuts, bolts and fittings should betight.

3. All suction and discharge piping should besecure.

4. All surfaces and joints should show no signsof leakage.

To re-grease bearings under the coupling guard,stop pump, lock the motor, remove the coupling

guard, then re-grease the bearings.

Need for Maintenance Records

A procedure for keeping accurate maintenancerecords is a critical part of any program to improvepump reliability. There are many variables thatcan contribute to pump failures. Analyzing these

variables through pump maintenance records canonly solve often-long term and repetitiveproblems.

Need for Cleanliness

One of the major causes of pump failure is thepresence of contaminants in the bearing housing.

This contamination can be in the form of moisture,dust, dirt and other solid particles, such as metalchips. Contamination can also be harmful to theseal (especially the seal faces) as well as otherparts of the pumps. For example, dirt in the

impeller threads could cause the impeller to notbe seated properly against the shaft. This, in turn,could cause a series of other problems. For thesereasons, it is very important that propercleanliness be maintained.

6.3 MAINTENANCETROUBLESHOOTING

The following is a guide to troubleshootingproblems with Wilfley pumps. Common problemsare analyzed and solutions are offered.Obviously, it is impossible to cover every possible

scenario. If a problem exists that is not covered byone of the examples, then contact a Wilfley SalesEngineer or Wilfley Distributor/Representative forassistance.

See next page.

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Table 5 Maintenance Troubleshoot ing

PROBLEM POSSIBLE CAUSE RECOMMENDED REMEDY

Pump notreaching designflow rate.

Problem #1

Insufficient NPSH.

Recalculate NPSH available. It must be greater than theNPSH required by pump at desired flow. If not, redesignsuction piping, holding the number of elbows and number of

planes to a minimum to avoid adverse flow rotation as itapproaches the impeller.System head greater thananticipated.

Reduce system head by increasing the pipe size and/orreducing the number of fittings.

Entrained air. Air leakfrom atmosphere onsuction side.

Check suction line gaskets and threads for tightness.If vortex formation is observed in the suction tank, installvortex breaker.Check for minimum submergence.

Entrained gas fromprocess.

Process-generated gases may require larger pumps.

Speed too low. Check motor speed against design speed.

Direction of rotation

wrong.

After confirming wrong rotation, reverse any two of threeleads on a three-phase motor.

The pump should be disassembled and inspected before it isrestarted.

Impeller too small.Replace with proper diameter impeller.NOTE: Increasing impeller diameter may require use of alarger motor.

Impeller clearance toolarge.

Reset impeller clearance.

Plugged impeller, suctionline or casing, which maybe due to a product orlarge solids.

Reduce length of fiber when possible.Reduce solids in the process fluid when possible.Consider larger pump.

Wet-end parts (casingcover, impeller) worn,

corroded or missing.

Replace part or parts.

Pump notreaching designhead (TDH).Problem #2

Refer to possible causesunder Problem #1.

Refer to remedies listed for Problem #1 & #3.

No discharge orflow.Problem #3

Not properly primed.Repeat priming operation and recheck instructions. If pumphas run dry, disassemble and inspect the pump beforeoperation.

Direction of rotationwrong.

After confirming wrong rotation, reverse any two of threeleads on a three-phase motor.

The pump should be disassembled and inspected beforeoperation.

Entrained air. Air leak

from atmosphere onsuction side.

Check suction line gaskets and threads for tightness.If vortex formation is observed in suction tank, install vortexbreaker.Check for minimum submergence.

Plugged impeller and/orsuction line casing, whichmay be due to a fibrousproduct or large solids.

Reduce length of fiber when possible.Reduce solids in the process fluid when possible.Consider larger pump.

Damaged pump shaftand/or impeller.

Replace damaged parts.


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Pump operatesfor short period,then loses

prime.Problem #4

Insufficient NPSH.

Recalculate NPSH available. It must be greater than theNPSH required by pump at desired flow. If not, redesignsuction piping, holding the number of elbows and number ofplanes to a minimum to avoid adverse flow rotation as itapproaches the impeller.

Entrained air. Air leakfrom atmosphere onsuction side.

Check suction line gaskets and threads for tightness.If vortex formation is observed in the suction tank, installvortex breaker.Check for minimum submergence.

Excessive noisefrom wet end.Problem #5

Cavitation insufficientNPSH available.

Recalculate NPSH available. It must be greater than theNPSH required by pump at desired flow. If not, redesignsuction piping, holding the number of elbows and number ofplanes to a minimum to avoid adverse flow rotation as itapproaches the impeller.

Abnormal fluid rotationdue to complex suctionpiping.

Redesign suction piping, holding the number of elbows andnumber of planes to a minimum to avoid adverse fluidcomplex suction piping rotation as it approaches the impeller.

Impeller rubbing.Check and reset impeller clearance.Check outboard bearing assembly for axial endplay.

Excessive noisefrom power end.Problem #6

Bearing contaminationappearing on theraceways as scoring,pitting, scratching orrusting caused byadverse environment andentrance of abrasivecontaminants fromatmosphere.

Replace bearings.Work with clean tools in clean surroundings.Remove all outside dirt from housing before exposingbearings.Handle with clean, dry hands.

Treat a used bearing as carefully as a new one.Use clean solvent and flushing oil.Protect disassembled bearing from dirt and moisture.Keep bearings wrapped in paper or clean cloth whilenot in use.Clean inside of housing before replacing bearings.Check oil seals and replace as required.Check all plugs and tapped openings to make sure that they

are tight.Brinelling of bearingidentified by indentationon the ball races, usuallycaused by incorrectlyapplied forces inassembling the bearing orby shock loading such ashitting the bearing or driveshaft with a hammer.

Replace bearings.When mounting the bearing on the drive shaft use a propersize ring and apply the pressure against the inner ring only.Be sure, when mounting a bearing, to apply the mountingpressure slowly and evenly.

False brinelling of bearingidentified by either axialor circumferentialindentations usuallycaused by vibration of theballs between the races ina stationary bearing.

Replace bearings.Where bearings are oil lubricated and employed in units that

may be out of service for extended periods, the drive shaftshould be turned over periodically to relubricate all bearingsurfaces at intervals of one to three months.Correct the source of vibration.


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(Cont.)Excessive noisefrom power end.

Problem #6

Thrust overload onbearing identified byflaking ball path on oneside of the outer race or,in the case of maximum

capacity bearings, mayappear as a spalling ofthe races in the vicinity ofthe loading slot. Thesethrust failures are causedby improper mounting ofthe bearing or excessivethrust loads.

Replace bearings.Follow correct mounting procedures for bearings.

Misalignment identified byfracture of ball retainer ora wide ball path on theinner race and a narrowercocked ball path on theouter race. Misalignmentis caused by poormounting practices ordefective drive shaft. Forexample, bearing notsquare with the centerlineor possibly a bent shaftdue to improper handling.

Replace bearings.Handle parts carefully and follow recommended mountingprocedures.Check all parts for proper fit and alignment.

Bearing damaged byelectric arcing identifiedas electro-etching of bothinner and outer ring or aspitting or cratering.Electrical arcing is caused

by a static electricalcharge emanating frombelt drives, electricalleakage or short-circuiting.

Replace bearings.Where current shunting through the bearing cannot becorrected, a shunt in the form of a slip-ring assembly shouldbe incorporated.Check all wiring, insulation and rotor windings to be sure that

they are sound and all connections are properly made.Where pumps are belt driven, consider the elimination ofstatic charges by proper grounding or consider belt materialthat is less generative.

Bearing damage due toimproper lubrication,identified by one or moreof the following:Abnormal bearingtemperature riseA stiff, cracked greaseappearance.

A brown or bluishdiscoloration of thebearing races.

Replace bearings.Be sure the lubricant is clean.Be sure proper amount of lubricant is used.In the case of greased, lubricated bearings, be sure thatthere is space adjacent to the bearing into which it can riditself of excessive lubricant; otherwise, the bearing mayoverheat and fail prematurely.Be sure the proper grade of lubricant is used.


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7.0 A7 WITH MECHANICAL SEAL DISASSEMBLY & REASSEMBLY

The following sections of this manual give instructions on how to perform a complete maintenance overhaul.However, it is also important to periodically repeat the Pre start-up checks listed on page 12. These checkswill help extend pump life as well as the length of time between major overhauls.

Refer to Figures 6 through 11 for item number references used throughout this section.

Note: The pictures in the following section represent typical parts to clarify assembly. Details of the parts maydiffer slightly from parts supplied with the pump.

ITEM NO. QTY. DESCRIPTION ITEM NO. QTY. DESCRIPTION

1 1 CASING 61N 5 CAP SCREW

1A 81 CAP SCREW 62 1 SHAFT

3* 1 CASE GASKET 62A* 1 BEARING, INBOARD14 1 IMPELLER 62B* 1 BEARING, OUTBAORD

61 1 BEARING FRAME 62C* 1 LOCKNUT61A 1 OIL FILL PLUG 67* 1 OIL SEAL, BEARING61B 1 OIL DRAIN MAGNETIC PLUG 72 1 BEARING CARRIER

61D 1 FRAME BRACKET 72A* 1 O-RING, BEARING CARRIER61E 1 FRAME FOOT 72B 3 J AM NUT61H 3 CAP SCREW 73 1 RETAINING RING61J 1 INBOARD BEARING COVER 75 6 CAP SCREW

61K* 1 INBOARD BEARING COVER GASKET 76* 1 OIL SEAL, OUTBOARD

61M 3 CAP SCREW 79 2 OIL SIGHT GLASS

Notes:

* Recommended spare parts1 Frame 3 has qty. 12 cap screws

Figure 6 - A7 Pump with Mechanical Seal

1

1A 61D 61N 61M 61 61A 73 62B*

75

62C*

76*

62

75

72B

72

62A* 61B 79 61E 61H 72A*67* 61J 61K*3*

14

SEE MECHANICALSEAL ASSEMBLY


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7.1 DISASSEMBLY

1. Before performing any maintenance,disconnect the driver from its power supplyand lock it off line.

Lock out power to driver to prevent personalinjury.

2. Close the discharge and suction valves anddrain all liquid from the pump.

3. Close all valves on auxiliary equipment andpiping, then disconnect all piping.

4. Decontaminate the pump as necessary.

If Wilfley pumps contain dangerouschemicals, it is important to follow plantsafety guidelines to avoid personal injury ordeath.

5. Remove the coupling guard.

6. Remove the spacer from the coupling.

7. Disconnect any seal drain piping.

8. Remove the fasteners holding the bearingframe (61) and case (1) to the baseplate.Remove pump and relocate to aworkstation.

It is important to follow plant safety

guidelines when lifting pump components.

9. Remove drain plug (61B) and drain oil fromthe bearing frame (61). Replace drain plugwhen done.

10. Remove the coupling hub from the pumpshaft.

11. Remove the fasteners (1A) holding thecasing to the bearing frame, remove casing(1) and discard the casing gasket (3).

12. Mount a shaft key and a shaft wrench to theend of the shaft (62). With the wrenchhandle pointing to the left when viewed fromthe impeller end, grasp the impeller firmlywith both hands (wear heavy gloves) andthen rotate it until the wrench handle is atthe 11 oclock position; next, spin theimpeller quickly in a counterclockwisedirection so that the wrench end makes asudden impact with a hard surface. Afterseveral sharp raps, the impeller should beloose. The shaft wrench can be fabricatedlocally, per the shaft wrench drawing (see p.42).

13. Unscrew the impeller and remove it from theshaft.

Do not apply heat to the impeller. Anexplosion could occur.

14. Remove the complete seal housingassembly.

15. Loosen the three jam nuts (72B) on thethree jacking bolts (75) on the bearingcarrier (72), then remove the three bolts.Loosen and remove the three retaining bolts(75).

16. Remove the bearing carrier assembly withthe shaft and bearings from the bearingframe and discard the o-ring (72A).

17. Remove the oil seals (67 and 76) from theframe and bearing carrier and discard them.

Further disassembly is not required unlessthe bearings are to be replaced.

Replacing the Bearings

1. Remove the snap ring (73) from the grooveof the bearing carrier (72).

2. The bearing locknut (62C) may now beremoved from the shaft.

3. An arbor or hydraulic press may be used toremove the bearings from the shaft. It isextremely important to apply even pressureto the inner bearing race only. Never applypressure to the outer race as this exertsexcess load on the balls and causes

DANGER!

DANGER!

CAUTION!

DANGER!


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damage. We recommend that all bearingsbe replaced after disassembly.

Applying pressure to the outer race couldpermanently damage the bearings.

7.2 CLEANING/INSPECTION

All parts should now be thoroughly cleaned andinspected. New bearings, o-rings, gaskets and oilseals should be used. Any parts that show wearor corrosion should be replaced with OEM Wilfleyparts.

Casing

Thoroughly clean gasket surfaces andalignment fits to remove rust and debris.

Inspect for any unusual erosive wear involute.

Impeller/Expeller

Inspect leading and trailing edges of vanesfor pitting, erosion or corrosion damage.

Frame

Inspect frame, bracket and frame foot forcracks.

Inspect for corrosion or pitting if frame hasbeen exposed to pumpage.

Inspect shafts and sleeves for wear.

Inspect frame bearing bores for roundness.

It is important that only nonflammable,noncontaminated cleaning fluids are used. Thesefluids must comply with plant safety andenvironmental guidelines.

7.3 CRITICAL MEASUREMENTAND TOLERANCES

To maximize reliability of pumps, it is importantthat certain parameters and dimensions aremeasured and maintained within specifiedtolerances. Any parts that do not conform to thespecifications should be replaced with new Wilfleyparts.

Shaft

The seal-mounting surface includes the shaftand/orshaft sleeve outside diameter within theseal housing and extending beyond toaccommodate outside seals. To provide for thepossible use of a mechanical seal, the toleranceof that diameter shall not exceed nominal minus0.002 in. (0.05 mm).

Shaft runout shall be limited as follows:

1. Shaft rotated on centers: 0.001 in.

(0.025mm) full indicator movement readingat any point.

2. Outside diameter of shaft or removablesleeve when installed on pump: 0.002 in.(0.05mm) full indicator movement at thegland end of the seal housing.

See next page.

CAUTION!

WARNING!


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7.4 ASSEMBLY

Assembly videos are available online at www.wilfley.com/support/instruction-videos.html or you can scan theQR code below with your smartphone:

Model A7 Pump Assembly

Full thread length engagement is required for all fasteners.Lightly lubricate all seal o-rings to prevent damage.

Figure 7 A7 Frame Assembly

1. Attach foot frame (61E) to frame (61) using fasteners (61H). Install pipe plugs (61A, 61B) and oilgauges (79) onto frame (61). Install cap screws (61M), inboard bearing cover (61J ) and inboardbearing gasket (61K) onto frame. Attach bracket (61D) with cap screws (61G).

61G

5

61M

361J 61K 79

61A

61

79

61E61B

61H

3

61D
http://www.wilfley.com/support/instruction-videos.htmlhttp://www.wilfley.com/support/instruction-videos.html


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Bearing Installation

Mounting of bearings on shafts must be done in a clean environment. Bearing and power-end life can bedrastically reduced if even very small foreign particles work their way into the bearings.Bearings should not be removed from their protective packaging until immediately before assembly to limitexposure to possible contamination. After the packaging is removed, bearings should only come into contact

with clean hands, fixtures, tools and work surfaces.

Note that the term inboard bearing refers to the bearing nearest to the casing. Outboard bearing refers tothe bearing nearest to the motor.

Both bearings have a slight and preferred interference fit that requires that they be pressed on the shaft withan arbor or hydraulic press. Even force should be applied to the inner race only. Never press on the outerrace, as the force will damage the balls and races. An alternate and preferred method of installing bearings isto heat the bearings to 200F (93C) in an oven or with an induction heater. Then place them quickly inposition on the shaft.

Never heat the bearings above 230F (110C). To do so will likely cause damage to bearing and seal.

Figure 8 A7 Shaft Assembl y Step 1

2. Install the retaining ring (73), outboard angular bearing (62B) and locknut (62C) onto the shaft (62).*Note: Use back-to-back bearing orientation when there are two angular contact bearings.* Then installinboard bearing (62A) onto shaft. It is recommended that a bearing heater be used when installingbearings to avoid damage to the races. Be sure the bearing seats against the shoulder of the shaft. Ifthe pump is grease lubricated, hand pack the bearings with the appropriate grease (reference Section8.0) after the bearings are seated on the shaft.

CAUTION!

62C

62B

73

62

62A


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Figure 9 A7 Shaft Assembl y Step 2

3. Install the outboard oil seal (76) into the bearing carrier (72). Please be sure that the notch in the sealfaces down for drainage. Install o-ring (72A) onto bearing carrier. Slide bearing carrier over the shaftand outboard bearing (62B) and install the retaining ring (73). Be sure the retaining ring is fully seatedin the groove.

Figure 10 A7 Shaft Assembly Step 3

4. Install the inboard oil seal (67) into the frame. To avoid damage, lubricate the o-ring with light oil andslide the assembly into the frame. The word top on the carrier must face up. Attach the bearingcarrier with three retaining bolts (75), jacking bolts (75) and jam nuts (72B). Clearance values andadjustment procedure follows the seal assembly steps. Attach square key (62D) onto shaft.

COMPLETEDASSEMBLYFROM STEP 1

72 72A

76

75

3

75

3

3

72B

62D

67COMPLETEDFRAME

ASSEMBLY

COMPLETEDASSEMBLYFROM STEP 2


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Figure 11 A7 Complete Pump Assembly

5. Install the mechanical seal according to the manufacturers guidelines.

6. Install the seal assembly to the frame. Be careful not to damage the shaft o-ring during assembly. Thetop of the seal housing has two bosses and the bottom has only one.

7. Seat the seal housing o-ring (30A) and the shaft sleeve o-ring (18) in their grooves.

8. Screw the impeller (14) onto the shaft. Be sure the impeller is securely tightened; use of a shaft wrenchis recommended to assist in the tightening process.

9. Install case gasket (3) onto the seal housing (30). Use a grease type substance to secure the gasket ifit does not stay in place.

10. Secure the casing (1) to the frame with the supplied bolts (1A).

11. Set the impeller clearances using one of the following methods and set the clearances according totable 6 below. Wilfley recommends that the dial indicator method be used to set the clearances.

1

14

3

1A

COMPLETE

SEAL ASSEMBLY


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Impeller Clearance

Cold temperature clearance (in.) for variousservice temperatures

Standard A7 Pump

See table below for clearances between casingand impeller.

Table 6 Casing and Impeller Clearances

+/- 0.001 Tolerance

Dial Indicator Procedures

Figure 12 Dial Indicator Method (PreferredMethod)

1. Set indicator so that button contacts the endof the shaft (62).

2. Loosen jam nuts (72B) on jacking bolts (75)and back jack bolts out two turns.

3. Tighten each retaining bolt (75) evenlydrawing the bearing carrier (72) towards theframe (61) until the impeller (14) contactsthe casing (1). Turn the shaft to ensurecontact is made.

4. Set indicator to zero and back the retainingbolts out one turn.

5. Tighten the jacking bolts so they evenly(about one flat at a time) move the bearingcarrier away from the frame until the

indicator shows the clearance for yourpump (see chart).

6. Evenly tighten all jack and retaining bolts sothat they are equally tight. Recheck the dialindicator to ensure the proper clearance hasbeen maintained.

7. Check shaft to be sure it turns freely.

Feeler Gauge Procedures

Figure 13 Feeler Gauge Method

1. Loosen jam nuts (72B) on jacking bolts (75)and back out approximately two turns.

2. Tighten each retaining bolt (75) evenly,drawing bearing carrier (72) towards theframe (61) until the impeller (14) contacts

the casing (1). Turn the shaft (62) to ensurecontact is made.

3. With a feeler gauge, set the gap betweenthe three sets of bolts and bearing carrierthat corresponds to the proper clearance foryour pump (see Table 1).

4. Evenly back out bearing carrier using thethree jacking bolts until it contacts theretaining bolts. Evenly tighten jam nuts.

5. Check shaft to be sure it turns freely.

Max.ServiceTemp.

Frame1

Frame2

Frame3

Frame4

200F

(93C)0.010 0.010 0.012 0.015

250F

(121C)0.012 0.012 0.014 0.017

300F(149C) 0.014 0.014 0.016 0.019


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7.5 ASSEMBLYTROUBLESHOOTING

See table below for possible assembly issues.

Table 7 Assembly Troubleshooti ng

SYMPTOM CAUSE

Excessiveshaft endplay.

Bearing internal clearance toogreat. Replace bearings withcorrect type. Snap ring loose inbearing housing groove. Reseat.

Excessiveshaft/sleeverunout.

Sleeve worn. Replace.Shaft bent. Replace.

Excessivebearing frameflange runout.

Shaft bent. Replace. Bearingframe flange distorted. Replace.

Excessiveframe adapter

runout.

Corrosion. Replace. Adapter toframe gasket not seated

properly. Reseat.Excessive sealhousing boxcover runout.

Seal housing not properlyseated in frame. Corrosion orwear. Replace.

Excessiveimpeller vanetip runout.

Bent vane(s). Replace impeller.

Reinstallation

1. Reinstall the pump to the base.

The pump should be reinstalled asdescribed in the installation section byfollowing the field installation and alignmentprocedures.

2. Install the coupling following themanufacturers installation instructions.

Install the coupling guard, ensuring that the guardis not in contact with the shaft and coupling.

Please refer to the pre start-up instructions.Follow all safety precautions and ensure that allsafety guards are in place.

See next page.

CAUTION!


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7.6 MECHANICAL SEAL TROUBLESHOOTING

Table 8 Mechanical Seal Troubleshoot ing


Mechanical seal hasshort life.

(and/or)

Mechanical seal leaksexcessively.

Misalignment due to pipe strain.

Check flange connections andeliminate strains using elastic

couplings or another permittedmethod.

Shaft bent.Check that shaft run-outs are withinacceptable values. Contact Wilfley.

Bearings worn. Replace bearings.Shaft sleeve worn or scored or runningoff center.

Check and renew defective parts.

Mechanical seal improperly installed.Check alignment of faces or damagedparts and assembly method used.

Incorrect type of mechanical seal foroperating conditions.

Consult Wilfley.Impeller out of balance, resulting invibration.

Abrasive solids in liquid pumped.Internal misalignment of parts preventseal ring and seat from properly mating.

Mechanical seal was run dry.Check mechanical seal condition andsource of dry running. Repair.

Internal misalignment due to improperrepairs, causing impeller to rub.

Check method of assembly, possibledamage, or state of cleanliness duringassembly. Consult Wilfley if needed.

Mechanical seal leaksexcessively.

Leakage under shaft sleeve due to jointfailure.

Replace joint and check for damage.


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8.0 LUBRICATION

Bearing Lubrication

Oil LubricationFill the frame until the oil level is approximately in the middle of the sight glass.

Table 9 Acceptable Oils

Chevron GTS Oil 68

Exxon Teresstic EP 68Gulf Gulf Harmony 68

Mobil Mobil DTE26 300 SSU 100F (38C)Phillips Mangus Oil Grade 315

Phillips MM motor Oil SAE 20-20W

Table 10 Lubricating Oil Requirements

Process Liquid Temp.< 300F

Process Liquid Temp.> 300F

ISO Grade VG 68 VG 100Approx . SSU at 100F (38C) 300 470

DIN 51517 C68 C100

Kinem. viscosity at105F (40.6C) in mm

2/sec

68 100

Table 11 Approximate Oil Volumes

Oil Volume

Frame 1 12 oz. [350 ml]Frame 2 51 oz. [1500 ml]Frame 3 51 oz. [1500 ml]

Frame 4 86 oz. [2500 ml]

Wilfley recommends that the oil be changed according to the customers preventive maintenance program.Every service can be different, which varies the length of time between oil changes. If a maintenanceprogram is already in place, follow that. If no program is in place, Wilfley recommends changing the pump oilonce every 3 months.

Grease LubricationBearings should be hand packed during assembly and reassembly.Further lubrication should be done per periodic servicing. Reference Section 6.2.Recommended grease: Grease SRI #2

9.0 ORDERING PARTS

Please include the serial number of your pump when ordering spare parts. With this number we can

determine and duplicate the original configuration and materials of construction.


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10.0 SPECIAL SERVICE

The seal assembly is extremely important to the total, efficient operation of Wilfley A7 pumps. Its parts,gaskets and seals must be in good working order. Many times parts are replaced unnecessarily due tounfamiliarity with the assembly. The reverse is also true: parts that should be replaced are, at times, left inthe assembly. For these reasons, we provide the service of rebuilding this assembly in our factory.

Your Wilfley A7 pumps and seals may be returned to the factory, at any time, for complete overhaul andrepair. Each pump is completely disassembled and worn or inoperable parts are replaced. All rebuiltpumps are subjected to the same testing procedures as newly constructed units. We charge thestandard price for parts and a minimal reassembly fee.

The utilization of this service provides you with almost instantaneous pump repair at an economical price.The units are overhauled and returned to you quickly.

Please contact A.R. Wilfley and Sons, Inc. or any of our authorized representatives at any time concerningour pumps or parts. You can be assured that we will do all within our power to ensure your completesatisfaction with Wilfley products.

A.R Wilfley and Sons, Inc.P.O. Box 2330Denver, Colorado 802011-(303) 779-17771-(800) 525-9930www.wilfley.com


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APPENDIX A SHAFT WRENCH

Figure 14 Shaft Wrench Drawing

Table 12 A7 Nominal Shaft Diameters

NOMINAL SHAFT DIAMETER W X Y Z

0.875 1.375 0.958 0.8780.880 0.1880.192

1.125 1.625 1.253 1.1281.130 0.1250.129

1.625 2.125 1.806 1.6281.630 0.3750.379

1.750 2.5 1.940 1.7531.755 0.3750.379

2.375 3.25 2.690 2.3782.380 0.6250.629

DIMENSIONS ARE IN INCHES

Z

W X

1.00

18

1.50

Y


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APPENDIX B A7 Bolt Torque Values

Table 13 A7 Bolt Torque Values

SAE Grade 2 (ft-lbs) SAE Grade 5 (ft-lbs)

Bol t Size TPI Torque Bol t Size TPI Torque

1/4 20 4 1/4 20 7

5/16 18 8 5/16 18 133/8 16 14 3/8 16 231/2 13 34 1/2 13 555/8 11 70 5/8 11 1103/4 10 110 3/4 10 2007/8 9 150 7/8 9 3201 8 225 1 8 480

1-1/8 7 350 1-1/8 7 5801-1/4 7 500 1-1/4 7 600*1-3/8 6 550* 1-3/8 6 600*1-1/2 6 600* 1-1/2 6 600*1-3/4 5 600* 1-3/4 5 600*

2 4.5 650* 2 4.5 650*

18-8 and 316 Stainless (ft -lbs) METRIC Class 8.8 (ft-lbs)

1/4 20 4 6mm 1.00 45/16 18 8 8mm 1.00 123/8 16 14 10mm 1.25 301/2 13 34 12mm 1.25 405/8 11 70 14mm 1.25 653/4 10 110 16mm 2.00 1007/8 9 150 18mm 2.00 135

1 8 225 22mm 2.50 2101-1/8 7 350 24mm 3.00 3151-1/4 7 500

1-3/8 6 550*1-1/2 6 600*

Note: Lubricate all fastener threads before tightening.

a7-iom-mech-seal-b.pdf

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