MT184CP

Teaching material

MT 184 Assembly and Maintenance Exercise: Piston Pump

10/2008

MT 184 ASSEMBLY AND MAINTENANCE EXERCISE: PISTON PUMP

All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Teaching material

Dipl.-Ing. Klaus-Jürgen Radtke

Dipl.-Geogr. Uta Linke

Version 1.0

i

Subject to technical alternations

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Technological principles of pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Classification and categorisation of pump types based on operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Designs and operating characteristics. . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 GUNT Practice Line kits and their usage . . . . . . . . . . . . . . . . . . . . . . 8

2.4 Operating characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4.1 Pump and system characteristics . . . . . . . . . . . . . . . . . . . . . 15

2.4.2 Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.4.3 Alteration of the operating point by restriction and variation of speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4.4 Operating characteristics of multiple interacting pumps . . . . 20

2.4.5 Intake characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . 21

3 Basics of pump maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.1 Definition Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2 Reasons for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.3 Detection of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.4 Checking pumps and replacing common wearing parts . . . . . . . . . . 27

3.5 Wearing parts in the pumps from the GUNT Practice Line for assembly and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.6 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.7 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.7.1 Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.7.2 Shaft and piston rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.7.3 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.7.4 Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

i

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

4 Technical description of piston pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.2 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.3 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.5 Dimensions of the piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.6 Parts drawings and parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5 Assembly and dismantling of the piston pump. . . . . . . . . . . . . . . . . . . . . . 59

5.1 Assembly of the piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.1.1 Assembly phase 1 – Crankshaft (assembly unit 1). . . . . . . . 60

5.1.2 Assembly phase 2 – Connecting rod with piston rod (assembly unit 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.1.3 Assembly phase 3 – Packing gland (assembly unit 3) . . . . . 69

5.1.4 Assembly phase 4 – Intake valve (assembly unit 4) . . . . . . . 73

5.1.5 Assembly phase 5 – Pressure valve (assembly unit 5) . . . . 77

5.1.6 Assembly phase 6 – Gearbox (assembly unit 6) . . . . . . . . . 81

5.1.7 Assembly phase 7 – Pump housing (assembly unit 7) . . . . . 91

5.1.8 Assembly phase 8 – Pump . . . . . . . . . . . . . . . . . . . . . . . . . 100

5.2 Dismantling the piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.2.1 Dismantling assembly phase 8 – Pump . . . . . . . . . . . . . . . 107

5.2.2 Dismantling assembly phase 7 – Pump housing . . . . . . . . 110

5.2.3 Dismantling assembly phase 6 – Gearbox . . . . . . . . . . . . . 113

5.2.4 Dismantling assembly phase 5 – Pressure valve . . . . . . . . 116

5.2.5 Dismantling assembly phase 4 – Intake valve . . . . . . . . . . 117

5.2.6 Dismantling assembly phase 3 – Packing gland . . . . . . . . 118

5.2.7 Dismantling assembly phase 2 – Connecting rod with piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.2.8 Dismantling assembly phase 1 – Crankshaft . . . . . . . . . . . 120

ii

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6 Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

6.1 Spare parts drawing and spare parts list . . . . . . . . . . . . . . . . . . . . . 123

6.2 Worksheet 1: Introduction to the piston pump, page 1 . . . . . . . . . . 130

6.3 Worksheet 2: Design, function and applications of the piston pump, page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

6.4 Worksheet 3: Identifying causes of faults, page 1 . . . . . . . . . . . . . . 135

6.5 Worksheet 4: Sealing systems, page 1 . . . . . . . . . . . . . . . . . . . . . . 136

6.6 Worksheet 5: Inspection of pumps, page 1 . . . . . . . . . . . . . . . . . . . 139

6.7 Worksheet 6: Servicing of pumps, page 1. . . . . . . . . . . . . . . . . . . . 141

6.8 Worksheet 7: Repairs to pumps, page 1 . . . . . . . . . . . . . . . . . . . . . 143

6.9 Worksheet 8: Wearing parts on the piston pump, page 1 . . . . . . . . 145

6.10 Worksheet 9: Assembling the piston pump, page 1 . . . . . . . . . . . . 147

6.11 Worksheet 10: Piston replacement, page 1. . . . . . . . . . . . . . . . . . . 153

6.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1 . . . . . . . . . . . . . . . . . . . 155

6.13 Worksheet 12: Spare parts ordering, page 1. . . . . . . . . . . . . . . . . . 163

7 Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

7.1 Spare parts drawing and spare parts list . . . . . . . . . . . . . . . . . . . . . 165

7.2 Worksheet 1: Introduction to the piston pump, page 1 . . . . . . . . . . 172

7.3 Worksheet 2: Design, function and applications of the piston pump, page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

7.4 Worksheet 3: Identifying causes of faults, page 1 . . . . . . . . . . . . . . 177

7.5 Worksheet 4: Sealing systems, page 1 . . . . . . . . . . . . . . . . . . . . . . 178

7.6 Worksheet 5: Inspection of pumps, page 1 . . . . . . . . . . . . . . . . . . . 181

7.7 Worksheet 6: Servicing of pumps, page 1. . . . . . . . . . . . . . . . . . . . 183

7.8 Worksheet 7: Repairs to pumps, page 1 . . . . . . . . . . . . . . . . . . . . . 185

7.9 Worksheet 8: Wearing parts on the piston pump, page 1 . . . . . . . . 187

iii

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.10 Worksheet 9: Assembling the piston pump, page 1 . . . . . . . . . . . . 189

7.11 Worksheet 10: Piston replacement, page 1. . . . . . . . . . . . . . . . . . . 195

7.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1 . . . . . . . . . . . . . . . . . . . 197

7.13 Worksheet 12: Spare parts ordering, page 1. . . . . . . . . . . . . . . . . . 205

8 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

9 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

iv

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

1 Introduction

The MT 184 practice kit forms part of the GUNT learning concept for pumpmaintenance, which is designed to aid education and training at trade acad-emies and corporate training centres.

A close link between theory and practice is key to the learning content.

We offer the following products relating to the subject of pump assembly andmaintenance:

This kit includes a piston pump.

Groups of two or three students working with one kit represents an optimalway of learning.

Pumps

Code Product

MT 180 Assembly and maintenance exercise - centrifugal pump

MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump

MT 182 Assembly and maintenance exercise - screw pump

MT 183 Assembly and maintenance exercise - diaphragm pump

MT 184 Assembly and maintenance exercise - piston pump

MT 185 Assembly and maintenance exercise - in-line centrifugal pump

MT 186 Assembly and maintenance exercise - gear pump

Tab. 1.1 Product relating to pump assembly and maintenance

1 Introduction 1

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

The following learning content is covered:

The teaching material includes a technical description detailing the basics ofpumps and dealing with the related maintenance.

The pump included in this kit is presented and described. Its assembly anddisassembly is demonstrated.

This section of the teaching material is intended to help tutors in preparingtheir own lessons. They may, of course, select information from it at their owndiscretion to use in their teaching.

The kit also includes prepared exercise sheets for the students, followed bythe relevant solutions.

The appendix includes the complete set of drawings for the pump, in the formof an assembly drawing with parts list, and including all manufacturing draw-ings for the individual components.

We very much hope you enjoy using this GUNT assembly practice kit, andwe wish you success in your important task of providing students and appren-tices with an introduction to the basic principles of the technology.

Learning content / Exercises

Design and function of a piston pump

Assembly and disassembly, including for maintenance purposes

Replacing components (e.g. seals)

Reading and understanding engineering drawings and operating instructions

Comparing different pumps(together with an additional kit forming part of this learning concept)

Tab. 1.2 Learning content / Exercises

1 Introduction 2

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

2 Technological principles of pumps

This chapter is designed to provide basic information for the following assem-bly and maintenance exercises from GUNT.

Wherever liquids are transported, produced or required to be supplied,pumps are deployed. The demands which they must met vary widely. A vastrange of fluids has to be conveyed, from highly sensitive pharmaceuticals,through large volumes of cooling liquid in power stations, to viscous chemicalproducts.

A wide variety of pumps have been developed over time for industrialapplications.

Not all pumps are mentioned in the following. Our outline presents astructured guide to the most common types of pump.

Code Product

MT 180 Assembly and maintenance exercise - centrifugal pump

MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump

MT 182 Assembly and maintenance exercise - screw pump

MT 183 Assembly and maintenance exercise - diaphragm pump

MT 184 Assembly and maintenance exercise - piston pump

MT 185 Assembly and maintenance exercise - in-line centrifugal pump

MT 186 Assembly and maintenance exercise - gear pump

2 Technological principles of pumps 3

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

2.1 Classification and categorisation of pump types based on operating principle

Pumps are fluid-flow machines which dictate how processes operate - that isto say, they ensure that flow takes place within systems.

In practice, pumps are often named after the liquid they pump or theirpurpose, such as milk pumps or cooling pumps. However, technicians andfitters can more easily identify their design when they are named accordingto their operating principle.

Fig. 2.1 Pump types

OscillatingSelf-priming

(Displacement device moves back and forth along an axis)

Normally priming(Not carrying gas, pumping from low level restricted)

RotatingSelf-priming

(Displacement device rotates in the pump body)

Self-priming(Carrying gas,

pumping from low level possible)

Piston pumps

Diaphragm pumps

Centrifugal pumps

Multi-stagecentrifugal pumps

Inline pumps

Gear pumps

Screwpumps

Side-channelpumps

Positive-displacement pumps

(Medium conveyed bydisplacement device)

Centrifugal pumps(A gyro causes

centrifugal forces to act on the medium)

Engines(Flowing medium drives machine)

Turbines

Machines(Machine drives a flowing medium)

Pumps

Fluid-flow machines


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

2.2 Designs and operating characteristics

The following table sets out the designs and operating characteristics of themost common positive-displacement pumps.

The piston pump incorporates an oscillating piston which is routed into a cylinder. The piston moves on an axis. The pump body is blocked by intake and pressure valves. A stroke gear drives the piston, which enlarges or reduces the pump chamber on every stroke.

By enlarging the pump chamber, the pumped fluid is drawn in by way of the intake valve. After a change of stroke the pump chamber is reduced and the pumped liquid is displaced by way of the pressure valve.

The diaphragm pump contains an elastomer diaphragm which is clamped into the pump housing. The oscillation is transferred from the stroke gear to the diaphragm by way of a thrust rod. The fluid feeds in and out by way of the valves, frequently executed as ball valves.

The method of operation is the same as the piston pump, with the diaphragm acting as the displacement device.

The gear pump contains two opposite rotating rigid or elastic gear wheels. The pump body is not closed off by valves.

The liquid is pumped by the rotating gear wheels from the intake to the delivery side in the gaps between the teeth along the pump wall. The gear meshing and narrow gaps between the rotor and housing minimise the reflux.

The screw pump consists of two or more spindles with helical splines which rotate inside a correspondingly shaped housing. The pump body is not closed off by valves.

The liquid is pumped axially in the free screw turns from the intake to the delivery side.

Here too, as in the case of the gear pump, the sealing from the delivery to the intake side is provided by narrow gaps.


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

The following table sets out the designs and operating characteristics of themost common centrifugal pumps.

The centrifugal pump contains a rotating, enclosed impeller with backward facing blades. The intake port is axially aligned to the pump shaft. The delivery port is aligned radially upwards.

The rotating impeller inside the pump body causes centrifugal forces to act on the pumped liquid. The liquid thrown out to the circumference of the pump by this flows out of the pump through the delivery port.

The multi-stage centrifugal pump is similar in design and action to the centrifugal pump. The difference is that is features multiple impeller arranged in a row on a shaft.

The pumped liquid passes from the intake port via the rotating impeller through a fixed guide channel to the next impeller, and so on, until it reaches the delivery port. The multistage impeller layout means the pump attains higher delivery heads.

The inline centrifugal pump is similar in design and method of operation to the centrifugal pump. Its intake and delivery ports are along one axis however, though here too the feed to the pump flows axially by way of an appropriately shaped housing. The inline pump is used in straight pipelines.


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Other special centrifugal pump designs

The side-channel pump contains a rotating starshaped open impeller with radially running vanes. It rotates inside a pump housing featuring a side channel which narrows from the inlet to the outlet.

The energy transfer acts on the medium by means of an exchange flow of the liquid in the impeller with that in the side channel. The side channel pump thus operates continuously with a self-priming effect, whereas the centrifugal pump is not self-priming.

The canned motor pump is similar in design and action to the centrifugal pump. It is leakage-free, as it requires no shaft seal. The drive of the canned motor pump is located practically inside the pump housing, and the pumped liquid flows around it.

The magnetic clutch pump is similar in design and action to the centrifugal pump. It is leakage-free and requires no shaft seal.

The magnetic clutch pump is driven by a non-contact magnetic clutch. The magnet on the pump shaft is inside the pump housing. It is separated from the magnet on the motor shaft by a tube.


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

2.3 GUNT Practice Line kits and their usage

The GUNT Practice Line kits for assembly and maintenance exercisesinclude the following pumps:

MT 180 – Centrifugal pump

Centrifugal pumps are in widespread use, and are primarily used to pumpfluid media. Their applications include in shipbuilding, industry and watersupply.

Fig. 2.2 Toolkit with parts set and pump

Fig. 2.3 Sectional drawing of the centrifugal pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

MT 181 – Multi-stage centrifugal pump

The multi-stage centrifugal pump is modular in design, and is used to pumpfluid media at higher delivery pressures. It is used in water supply and inindustry.


Fig. 2.5 Sectional drawing of a similar multi-stage centrifugal pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

MT 182 – Screw pump

Screw pumps are primarily used to transport viscous media such as lubricat-ing oil, plant oil, glycols and polymers. Their applications include lubricationsystems for diesel engines and transmissions, as well as in hydraulicsystems.


Fig. 2.7 Exploded-view drawing of the screw pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

MT 183 – Diaphragm pump

Diaphragm pumps are absolutely leakage-free and, provided appropriatematerials are selected, are particularly well suited to pumping aggressivefluids such as acids and caustic in chemical engineering applications.Diaphragm pumps are often used for volumetric metering, as meteringpumps.


Fig. 2.9 Sectional drawing of the diaphragm pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

MT 184 – Piston pump

Piston pumps are used primarily to transport fluids at high delivery pressuresand low flow rates. Typical applications include pumping drinking water anddomestic water in residential areas, in agriculture, onboard ships and inindustry.


Fig. 2.11 Drawing of the piston pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

MT 185 – Inline centrifugal pump

In-line centrifugal pumps are a sub-category of centrifugal pumps. Inlinepumps are installed in straight pipelines. They are required in applicationsincluding water supply, watering and sprinkler systems, and in heating engi-neering.


Fig. 2.13 Exploded-view drawing of the in-line centrifugal pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

MT 186 – Gear pump

Gear pumps are of the rotating positive-displacement pump category, andare characterised by pulsation-free delivery at operating pressures up to40bar. High-viscosity media such as oils, paints and adhesives can bepumped.


Fig. 2.15 Exploded-view drawing of the gear pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

2.4 Operating characteristics of pumps

Alongside preventive maintenance, repair work forms a key part of generalservice operations. Damage to pumps can be traced back to incorrect oper-ation in more than 50% of cases.

It is advantageous for the assembly personnel to have basic knowledge ofhow the pump operates and are aware of how to use the pump correctly.

2.4.1 Pump and system characteristics

The delivery capacity of a pump is indicated by the pump’s characteristiccurve. The delivery rates are measured on the test stand at the respectivedelivery pressures. The pump measurement data is depicted in the form of acharacteristic curve. Usually the delivery head is given in place of the deliv-ery pressure (as a result the characteristic curves of centrifugal pumps arenot dependent on the density of the pumped liquid).

In the case of centrifugal pumps the dependency of the delivery rate on thehead is marked: As the head rises, the delivery rate decreases significantly.By contrast, the delivery rate of positive-displacement pumps remains virtu-ally constant as the head rises.

In the case of positive-displacement pumps, it must be ensured that thepermissible operating pressure is not exceeded. Overflow valves arefrequently used for this.

Fig. 2.16 Characteristic curve fora centrifugal pump

Fig. 2.17 Characteristic curve fora positive-displacement pump

Delivery QDelivery Q

Hea

d H

Hea

d H


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Operation of the positive-displacement pump with the overflow valve(partially) open is depicted in the horizontal segment of the curve (see Fig.2.17).

The graph gives an indication of the delivery capacity of the pumps, thoughit provides no information on the delivery data actually achieved.

An often cited problem when operating pumps is that the pump does notreach the necessary pressure. Generally speaking, pumps only deliver mate-rial; the associated pressure is caused by the system.

The system operating data can likewise be measured and depicted graphi-cally in the system characteristic curve. As the delivery rate increases, thesystem pressure - determined by practical calculation - rises.

Fig. 2.18 System characteristic curve

Delivery Q

Hea

d H


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

2.4.2 Operating point

The actual delivery data result from the interaction of the pump and thesystem.

If the pump and system curves are plotted on the same diagram, the point atwhich the curves intersect is the operating point.

So if the operating data do not conform to the specification, the technicianshould first check and calculate the correct operation of the pump in thesystem. This should be done on initial commissioning and every time thesystem is modified.

Fig. 2.19 Operating point (1) of anormally priming centrifugalpump

Fig. 2.20 Operating point (1) of apositive-displacement pump


Hea

d H

Hea

d H

1

1


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

2.4.3 Alteration of the operating point by restriction and variation of speed

In practice, restriction is frequently used to set the desired delivery rate. Theflow is restricted by partially closing a valve on the delivery side of the pump.This results in a new system curve with a steeper rise. The new operatingpoint 2 is the point of intersection of the new system curve with the pumpcurve. Or in other words: The operating point has shifted along the pumpcurve from 1 to 2.

While the delivery rate decreases as the head rises on a centrifugal pump,the delivery of a positive-displacement pump remains constant as thepressure rises.

Fig. 2.21 Shift in operating point from (1) to (2) by restriction for a normally priming centrifugal pump

Fig. 2.22 Shift in operating point from (1) to (2) by restriction for a positive-displacement pump


Hea

d H

Hea

d H

1

2

2

1


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

A common method of shifting the operating point of a pump is to vary thespeed. The speed is varied by means of an adjuster gear or a frequencyinverter. This produces a new pump characteristic curve.

The diagrams show an increase in speed from n1 to n2 for both pump types(see Fig. 2.23 and Fig. 2.24). In the case of the centrifugal pump, the pumpcurve moves upwards, while for the positive-displacement pump it shifts tothe right.

In both diagrams the operating point shifts upwards along the system curve.That is to say, higher heads and delivery rates are produced as the speedincreases.

Fig. 2.23 Influence on the pump characteristic of a variation in speed for a normally priming centrifugal pump

Fig. 2.24 Influence on the pump characteristic of a variation in speed for a positive-displacement pump


Hea

d H

Hea

d H

n1

n2

n1

n2


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

2.4.4 Operating characteristics of multiple interacting pumps

Operation of multiple pumps simultaneously in a system is quite common,and in many cases essential in order to conform to extreme operating speci-fications.

If multiple pumps are configured in parallel, the delivery rate is increased. Ifpumps are configured in series (one behind the other), the delivery headsare added together.

The pump industry has made use of these properties and developed anumber of designs accordingly.

Multi-flow pumps achieve high delivery rates, multi-stage pumps achievehigh heads.

Fig. 2.25 Parallel configuration Fig. 2.26 Series configuration

Fig. 2.27 Multi-flow pump, sectional view and delivery principle

Fig. 2.28 Multiple-stage pump, sectional view and delivery principle


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

2.4.5 Intake characteristics of pumps

Attention must be paid to the intake characteristics of the pumps. A distinc-tion is made between selfpriming and nonselfpriming pumps.

The normally priming centrifugal pump is a non-self-priming pump. It is notcapable of pumping a gaseous medium out of the pump body. It must alwaysbe ensured that a liquid is fed in from a higher level, or where the feed is froma lower level, the liquid head does not collapse, such as due to the use of footvalves on the intake side.

Fig. 2.29 Infeed of a pump system for a normally priming pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Self-priming pumps include side channel pumps (see chapter 2.2, page 5).They are capable of pumping gases. However, the pump body must alwaysbe filled with liquid for this to happen. That is why the intake and delivery portson side channel pumps always point upwards.

Most positive-displacement pumps are self-priming. The displacementdevice is able to compress the gas and displace it out of the pump body. Forthis to happen, however, the pump must be partially filled with liquid, becauseonly wetted valves close exactly such that no reflux is possible. This alsoapplies to rotating positive-displacement pumps, of which the wetted gapsrestrict reflux.

Fig. 2.30 Intake of a pump system for a self-priming pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3 Basics of pump maintenance

3.1 Definition Maintenance

All pump operators should maintain their pumps in accordance with the main-tenance and operating instructions issued by the manufacturers. Mainte-nance is the umbrella term for inspection, servicing and repair (see Fig. 3.1).A log book or machine file should be set up for each pump unit, indicating thecurrent status and the repair work carried out to date.

Fig. 3.1 Maintenance

Replacement,Correction

With the system running and at stand

still based oninspection instructions

Only with the system stopped, based on

specific work order and after careful preparation

Only withsystem stopped

according tomaintenance instructions

MAINTENANCE TO DIN 31051

Inspection RepairsServicing

Recording and assessment of the

current actual status

Restoration of the specified status

Preservation of thespecified status

Measurement,Testing,

Diagnosis

Cleaning,Lubrication,Adjustment

3 Basics of pump maintenance 23

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3.2 Reasons for maintenance

Pumps are required for the operations of many manufacturing systems. If thepumps are malfunctioning, there is a risk of production outages. Appropriatemaintenance is a key factor determining the productivity of operations.

Complete replacement of the pump is possible in the event of a defect,though it is not always essential and, especially, is not necessarily cost-effec-tive. Carrying out preventive maintenance and servicing, as well as repairs,is advantageous. A number of reasons are cited by way of example.

• The cost of purchasing a mid-sized industrial pump is considerable. Theannual cost of wearing parts amounts to around 10% - 20% of thepurchase price of the new pump.

• Holding a complete replacement pump in stock is inefficient and expensivefor many businesses. It is, however affordable, and advisable, to holdstocks of key pump spares.

• The delivery lead times for complete pumps are usually lengthy, whereasspares can be supplied from suppliers’ central stores at short notice.

• Fig. 3.2 shows that routine maintenance of pumps (2) results in lower costsin the medium and long term than complete replacement of pumps (1).

Fig. 3.2 Total cost, comparison of replacement (1) and maintenance (2)

Service life

Cos

t 1

2


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3.3 Detection of faults

Many factors need to be considered in order to ensure optimised, trouble-freeoperation of pumps. Nevertheless, faults will routinely occur. A number ofbasic points need to be observed in order to assess faults and their causes:

• The specifications of the delivery medium need to be considered in orderto ensure long service life of the pumps. The material durability of thepump components and seals must be ensured. The design and construc-tion of the pump must be attuned to the specific pumping requirements.

• Most pumps are driven by electric motors. Attention must be paid tocorrect dimensioning and selection.

• Incorrect electrical connections and setting the incorrect direction ofrotation are often sources of faults resulting in production problems.

• As a general rule applicable to all pumps, lengthy periods of dry runningshould be avoided, as this would substantially shorten the service lives ofthe shaft seal, piston seal and valves. The delivery medium providesadditional lubrication of those components. This principle is illustrated bythe example of the floating ring seal in Fig. 3.3.

There must always be a liquid film between the contact faces of a floating ringseal.

Fig. 3.3 Floating ring seal with liquid film


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

During inspection of the pump, checks should be made regularly while thepump is running to ensure early detection of faults, focussing in particular onthe following points:

• Leakage

• Noise

• Smooth running

• Temperature

• General condition

The reasons for pump faults are many and varied.

System-related disturbances such as pressure surges should be avoided oreliminated. Incorrectly switching system valves may stop the pumped liquidto an extreme degree, causing overlaid liquid waves to form which result inpressure surging as far as into the pump.

Trapped foreign bodies cause significant damage inside the pump.Deformed shafts, destroyed bearings and valves, as well as scraping impel-lers, are the consequences of such disturbances. Even tiny abrasive particleswill cause long-term damage to the pump and the seals.

The occurrence of cavitation is a system fault which needs to be prevented.

If the infeed line to the pump is incorrectly dimensioned, it is possible that avacuum will created in the intake port, causing the medium to boil. Theincrease in pressure in the pump causes the boiling bubbles to implode,thereby destroying the housing and impeller.

Fig. 3.4 Cavitation damage to a pump impeller


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3.4 Checking pumps and replacing common wearing parts

In accordance with the service intervals specified in the manufacturers’ main-tenance instructions, which are additionally dependent on the specific oper-ating conditions, it is advisable to check pumps about once a year.

Bearings

The operating instructions specify that the lubricant should be changed onpumps with an enclosed gear and bearing unit.

Modern-day greased bearings are lifetime-lubricated, and merely need to bechecked for smooth running.

Shaft seals

Packing glands and floating ring seals are checked for leaks and wear.

Glands can be adjusted, if still possible. The gland packing should bereplaced after about 2000 operating hours.

The service lives of the floating ring seals are considerably longer. They arereplaced in full if worn.

Couplings

Pumps coupled to their drives by flexible couplings should be checked forflush coupling. The power-transmitting components should be checked forwear and replaced as necessary.


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Pump internals

The pumps should be opened and their internals checked for wear andcorrosion at the specified servicing intervals.

In the case of centrifugal pumps, as well as the shaft seal the static seal ringmust be checked and replaced if worn.

The valves of reciprocating pumps, including their sealing faces, should bechecked. Piston rings and packing should be checked for wear, and theplungers and sleeves checked for scoring.

Fig. 3.5 Pump unit with listed wearing part groups

20Pump internals

Bearing Coupling

Shaft seal


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3.5 Wearing parts in the pumps from the GUNT Practice Line for assembly and maintenance

It should be stated by way of preamble that, according to the state of the artin centrifugal pumps, bearings are no longer classed as wearing parts.

MT 180 – Centrifugal pump

MT 181 – Multi-stage centrifugal pump

Fig. 3.6 Sectional drawing of the centrifugal pump

Fig. 3.7 Sectional drawing of a similar multi-stage centrifugal pump

Shaft seal(gland)

Housing seal

Housing/stage sealPacking gland Floating ring seal


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

MT 182 – Screw pump

MT 183 – Diaphragm pump

The wearing parts mentioned should be replaced during servicing.

Fig. 3.8 Exploded-view drawing of the screw pump

Fig. 3.9 Sectional drawing of the diaphragm pump

Floating ring seal

Housing sealHousing seal

Valves

Oil filling

Diaphragm

Journal bearing


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

MT 184 – Piston pump

MT 185 – Inline centrifugal pump

Wear is to be expected on the parts marked, necessitating replacement ofthem.

Fig. 3.10 Drawing of the piston pump

Fig. 3.11 Exploded-view drawing of the in-line centrifugal pump

Piston sealOil filling

Piston rod seal

Valves

Housing seal Floating ring seal


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

MT 186 – Gear pump

Any well organised maintenance department should hold stocks of thewearing parts on the various pumps mentioned in this chapter.

Fig. 3.12 Sectional drawing of the gear pump

O-rings

Floating ring seal

Housing sealJournal bearingWear disc


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3.6 Shutdown

In systems in which uninterrupted running of pumps is extremely important,such as in power stations or onboard ships, replacement units are installedfully piped-up as standby units. This allows servicing or repairs to be carriedout during live operation, by switching to the standby unit.

In most production environments, maintenance can only be carried out duringproduction downtimes - that is, at partial or complete standstill. The pumpsshould be integrated into the system in such a way that short-interval servic-ing can be carried out without removing them. That is to say, they must beeasily accessible for inspection and servicing. On the pump intake side andthe delivery side stop valves should be installed.

In the case of positive-displacement pumps, the drive unit is first shut down.Immediately after the pump stops the delivery-side valve is closed, then theintake side is closed. If non-return valves are installed, they automatically actas stop valves. So installed non-return valves on the delivery side, for exam-ple, prevent possible reflux to the pump.

In the case of centrifugal pumps, the delivery-side valve is first closed, thenthe drive is shut down, and then the intake side is closed.

Before opening the pump, the pump and the connected piping system mustbe drained. This can be done either by way of sealing plugs or by carefullydetaching the pipe fittings.

If the pump unit is removed completely from the system for major mainte-nance work, the safety guidelines issued by the drive manufacturers mustadditionally be followed.

Fig. 3.13 Installation with standby pump

Fig. 3.14 Single pump with stop valves


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3.7 Repairs

Whereas during servicing parts are usually replaced following checking andas required, during repair complete wearing parts or defective componentsare replaced after predetermined operating cycles. These cycles are eitherspecified by the manufacturers or they are determined by the identifiedcondition of parts at the various maintenance intervals.

It is advisable to schedule every second to third service as a repair operation.

3.7.1 Static seals

Flat seals and O-rings used for sealing between metal components and toprevent escape of liquid from the pump body are replaced completely. Theirlocations include at the connection fittings and on the housing covers, floatingring seals, shaft sleeves and valves.

Procedure:

• Dismount the pump

• Remove the seals and dispose of them

• Clean the parts

• Install the new seals during reassembly

• Avoid mechanical damage. Ensure cleanliness. Grease seals where necessary.


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Fig. 3.15 O-rings in a centrifugal pump

Static seals

Static seals

Static seal


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3.7.2 Shaft and piston rod seals

The most varied stresses on seals in pump engineering occur in the sealingof shaft and piston rod feed-throughs. These seals must act between areassubject to different pressures, and are subject to the demands of a widevariety of media, as well as having to withstand additional physical strainscaused by rotating shafts or oscillating piston rods. These types of seal areknown in engineering as dynamic seals. Operators expect reliable sealing,with minimal leakage, over a long service life. The shaft seals in particularshould be preventively replaced during scheduled repair work, because ofthe extreme stresses to which they are subject.

Fig. 3.16 Example of a piston rod seal

Fig. 3.17 Example of a shaft seal

Piston rod seal

Shaft seal


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

A tried and proven method of sealing shafts is by means of soft packingglands.

This packing consists of a woven cord made principally of solid fabrics whichis inserted in the packing space between the shaft and the housing, where itis deformed by an axial force and so moulded to the surfaces it is intended toseal.

To seal the pump shaft, packing glands (1) are used. These are provided ina wide range of materials and designs depending on the pump application.To protect the shaft, a shaft sleeve (2) is installed. Locking rings or ancillaryglands (3) hold the packing in place. The gland press (4) compresses thepacking by way of screw fittings. Correct functioning demands careful assem-bly and commissioning.

Fig. 3.18 Example of a gland Fig. 3.19 Packing gland packing

1

2

4

3


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

When packing a new gland the following points need to be considered:

• Correct choice of packing based on quality and dimensions

• Completely remove old packing residues (3)

• The shaft protective sleeve (7) must be free of surface damage

• Insert the packing (3) with offset interfaces

• Use of sharp tools will damage the gland

• Tighten the gland press (5) by screws after inserting the packing, thenslacken it slightly

• The pump shaft (2) must be loose enough to be turned slightly by hand

Fig. 3.20 Packing gland of a centrifugal pump, sectional view with zoom

Item Name

1 Washer

2 Shaft

3 Packing gland packing

4 Locking ring

5 Packing gland press

6 Stud bolt with hexagonal nut

7 Shaft sleeve

8 Housing cover


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Only tighten up the gland press after a run-in time of about 20-30 minuteswith leakage of 50-100 drops per minute

• Adjust the gland to the required leakage rate of 3 drops per minute

To seal shaft lead-throughs which are subject to high stresses, floating ringseals are the most advantageous option nowadays. They are available in awide range of designs, dimensions and frictional material pairings. Correctlyselected, fitted and operated floating ring seals will permit longer-lastingoperation of rotating positive-displacement and centrifugal pumps, with lessleakage, then packing glands.

Floating ring seals are contact seals which create a yielding seal connectionbetween stationary and rotating contact faces. Between the contact faces isa film of liquid, which assumes a stable position due to the centrifugal forceoccurring during rotation. The floating ring seal is sealed against the housingby means of static elastomer seals (1). The floating ring (2) rotating with theshaft is held axially in place relative to the counter-ring (4) fixed in the housingby a spring (3). The contact faces thus automatically adjust axially. Even highpressures can be controlled by means of hydraulic relief.

Fig. 3.21 Drawing of a floating ring seal

13 2 4


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8
Procedure for replacing the floating ring seal on a centrifugal pump shownbelow:
• Shut down the pump

• Open the pump cover (1)

• Slacken the impeller nut (2)

• Detach the impeller (3) from the shaft

• Remove the floating ring (4) from the shaft

• Pull the counter-ring (5) out of the housing using a suitable implement

• Assemble in the reverse order of removal

Fig. 3.22 Floating ring seal

Fig. 3.23 Example of replacing a floating ring seal on a centrifugal pump

4 1

2

3 5


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

In view of the wide range of floating ring seal designs and pump versions,methods of removal and fitting vary. The principle illustrated here is that appli-cable to the most frequently used centrifugal pump.

The piston rod sealing in oscillating motions of the piston rods and plungersof the piston pumps is achieved by using packing glands, lipped rings,grooved rings (1) and conical rings held in support rings (2). The design andmaterials must always be selected to match the given operating conditions.Spring-loaded (3) seals, for example, offer uniform pre-tension, low frictionand so longer service lives.

The method of removal and fitting depends on the specific pump version anddesign. The manufacturers’ fitting instructions are useful in this context, andshould be followed.

Fig. 3.24 Drawing of a piston rod seal

1 3 2


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

The same is true of the piston seals. Replacing piston rings and pistonsleeves forms part of the essential scheduled repair routine. Some designvariants are shown in Fig. 3.25.

Fig. 3.25 Examples of piston seals

Piston with leather/rubber sleeves

Piston with metal seal rings

Piston with hemp stricks


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3.7.3 Valves

Positive-displacement pumps such as reciprocating pumps and diaphragmpumps seal off the delivery space by means of intake and delivery sidepressure valves. They open due to the resultant pressure difference on everystroke and close due to their intrinsic mass or by additional spring force.

The valves of the smaller diaphragm pumps, used as metering pumps in thechemical industry, are executed as ball valves. Owing to the more preciseeffect achieved, twin ball valves are often installed. They are replaced bysimply unscrewing the valve unit out of the housing.

The valves of the piston pumps may be executed as weight or spring-loadeddisc valves.

The sealing faces are mostly metallic, and correspondingly sensitive.

After being individually removed, the discs are replaced. The valve seats arechecked and re-milled or lapped as necessary. In the case of valves with anadditional elastomer sealing disc, only the disc needs to be replaced, and thesmooth running checked.

Fig. 3.26 Twin ball valve of a diaphragm pump


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

3.7.4 Spare parts ordering

Maintenance work should generally be carried out on a routine basis inaccordance with the maintenance instructions and safety rules laid down bythe manufacturers. Key parts should be replaced at the maintenance inter-vals indicated in the operational or machine log. Arrangements should bemade for parts to be procured from the supplier in advance.

Every pump has a rating plate affixed to it by the manufacturer. The ratingplate indicates the manufacturer’s name, the pump model and serial number.The data is often also imprinted on the housing, so the information is stillavailable even if the rating plate comes off. Based on this information, theexact technical and material specification can be identified.

Fig. 3.27 Examples of disc valves

Spring-loaded with flat seat and seal ring

Spring-loaded with flat seat Weighted with conical seat


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

The details shown in Fig. 3.29 need to be quoted to the supplier when order-ing spares, so as to ensure the correct parts are supplied:

Fig. 3.28 Example of a housing with imprinted model and serial number

Fig. 3.29 Information for spare parts ordering, e.g. identified from rating plate, parts drawing or parts list

1. Pump model

2. Serial number

3. Part name

4. Item number on parts list


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

4 Technical description of piston pump

4.1 Description

Piston pumps are used primarily to transport fluids at high delivery pressuresand low flow rates.

At constant speed, the volumetric flow also remains constant at differentpressures. A air chamber built-in to the pump damps the pressure spikeswhich occur on each stroke.

The pump presented here is a double-acting piston pump, which means thateach stroke is simultaneously an intake and a delivery stroke.

The pump incorporates a safety valve, so that if the pressure rises too high aportion of the flow is returned to the intake side.

Typical applications of piston pumps include pumping drinking water anddomestic water in residential areas, in agriculture, onboard ships and inindustry and at commercial garden centres.

Fig. 4.1 Piston pump

4 Technical description of piston pump 46

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

4.2 Mode of operation

The piston pump is driven by way of a pulley and a V-belt by an electric motor.On every revolution, the crankshaft acts by way of the connecting rod and thecrosshead on the piston (1) which is mounted on the end of the piston rod.This stroke motion causes the piston to move back and forth in the cylinderbushing (2).

On every stroke the piston (1) enlarges and reduces the size of the deliverychamber. In the enlarging delivery chamber a negative pressure is created,causing the pressure valve (3) to close and liquid to flow via the intake valve(4) into the delivery chamber. In the reducing delivery chamber the pistonpresses the liquid via the pressure valve out of the pump body, while theintake valve is pressed closed. The piston pump investigated here has adelivery chamber on each side of the cylinder bushing. The pump is double-acting, since on every stroke it simultaneously draws in on one side anddisplaces on the other.

If the pressure on the delivery side (5) of the pumps is too high, the built-insafety valve (7) opens and the liquid flows inside the pump back to the intakeside (6).

Fig. 4.2 Delivery principle of a double-acting piston pump

Item Name

1 Piston

2 Cylinder bushing

3 Pressure valve

4 Intake valve

1

4

3

2


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

The piston pump is self-priming. It must, however, be primed prior to initialcommissioning.

The pump delivery is independent of the direction of rotation of the drive.However, optimum lubrication of the gearbox can only be effected in thedirection indicated by the arrow on the pump.

Fig. 4.3 Delivery principle of the piston pump

Item Name

3 Pressure valve

4 Intake valve

5 Delivery Side

6 Intake side

7 Safety valve

7

3 4

65


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

4.3 Layout

The layout of the piston pump is shown in the drawings (see chapter 9, page209). The pump consists of the following main components:

• Air chamber with safety valve

• Pump housing with valves

• Piston

• Gland

• Crankshaft

• Crosshead

• Piston rod

• Gearbox housing

Fig. 4.4 Component assemblies of the piston pump

2

1

4765

8

3

Item Name Item Name

1 Air chamber with safety valve 5 Crankshaft

2 Pump housing with valves 6 Crosshead

3 Piston 7 Piston Rod

4 Packing gland 8 Gearbox housing


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

The motor is mounted on the pump unit by clamp rails.

The crankshaft, the connecting rod and the crosshead are automaticallylubricated in the gearbox housing by circulating oil on every rotation.

The piston rod is sealed off from the delivery chamber by a packing gland.

The sleeved piston made of NBR rubber runs in a stainless steel cylinderbushing.

The two delivery chambers each contain two disk valves with valve rubberplates.

The delivery side of the pump is executed as a air chamber, with a built-insafety valve.

4.4 Technical data

Pump model: PM 10

Power consumption: max. 0,37 kW

Max. capacity: 1000 ltr/h

Max. delivery pressure: 6 bar

Motor speed: 1450 rpm(driven by V-belt)

Intake connection: 1 “

Pressure connection: 1 “

Pump materials:

Pump body: GG20

Valves: Brass (CuZn39Pb3)

Cylinder bushing: X6CrNi18-10

Piston: NBR

Piston rod seal: PTFE saturated packing rings


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

4.5 Dimensions of the piston pump

Fig. 4.5 Dimensions


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

4.6 Parts drawings and parts lists

Fig. 4.6 Spare parts drawing for the piston pump

83, 8

7

81, 8

2

79, 8

084

, 85

8779

, 80

85, 8

6

8


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Fig. 4.7 Spare parts drawings for the gearbox

19

6

22

21

4, 23

16

11

3 - 15

8

20

10

3435 14

171833

2

321227913 29282657 1 30,31 24 25


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Fig. 4.8 Spare parts drawings for the pump housing

4245 63 43

4060

51

50, 5

2, 5

3

59

39

65

47

4861

7462

46, 7

776757372

4767

6658

41

54 68

69

7071

4457

58

3849

373664


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Item Quantity

Unit Name Item number / Standard

Comments

1 1 Piece Connecting rod MT184.10.04.001

2 1 Piece Packing gland housing MT184.10.05.002

3 1 Piece Crankshaft MT184.10.03.001

4 1 Piece Bearing cover, open MT184.10.10.001

5 1 Piece Gearbox housing MT184.10.09.001 EN-GJL-200

6 1 Piece Bearing cover, closed MT184.10.09.002 EN-GJL-200

7 1 Piece Gearbox cover MT184.10.09.003 DOC04

8 1 Piece Base plate MT184.10.09.004 S235JR

9 1 Piece Oil splash guard MT184.10.09.005 DOC04

10 1 Piece Packing gland seal MT184.10.09.006 SBR/B-870M

11 2 Piece Bearing cover seal MT184.10.09.007 SBR/B-870M

12 1 Piece Oil stripper MT184.10.09.008 60NBR693 SW

13 1 Piece Oil plug MT184.10.09.009 CuZn39Pb3

14 1 Piece Duo-piston PM10 Simirit

15 1 Piece Disk spring DIN 6888-5x7,5

16 8 Piece Hexagon nut ISO 4032-M6 8


18 1 Piece Spring ring DIN 127-A-8 A2

19 6 Piece Hexagon screw ISO 4017-M6x12 8.8

20 4 Piece Rubber buffer 500029 GMT

21 2 Piece Seal DIN 7603-A-10x13,5x2

PVC

22 2 Piece Angled oiler with nut G1/8 Spike

23 1 Piece Radial shaft seal DIN 3760-A-16x35x7

NBR

24 2 Piece Grooved ball bearing DIN 625-6202


Tab. 4.1 Spare parts list


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

26 1 Piece Crosshead MT184.10.04.002 EN-GJL-200

27 1 Piece Piston Rod MT184.10.04.003 X14CrMoS17

28 1 Piece Straight pin ISO 8734-12x35 C1

29 1 Piece Hexagon nut ISO 4032-M8 8-A2



32 1 Piece Packing gland screws MT184.10.05.002 CuZn39Pb3

33 1 Piece Brass washer MT184.10.05.003 CuZn37F30

34 1 Piece Gland packing 00.2251 Spike

35 1 Piece Lip seal ISO 4032-M8 A2-70

36 1 Piece Lock nut MT184.10.09.002 CuZn39Pb2

37 1 Piece Knurled screw MT184.10.08.003 CuZn39Pb3

38 1 Piece Cap MT184.10.08.004 NBR

39 1 Piece Pump housing MT184.10.06.001 EN-GJL-200

40 1 Piece Cylinder cover MT184.10.06.002 EN-GJL-200

41 1 Piece Air chamber MT184.10.06.003 EN-GJL-200

42 1 Piece Water plug MT184.10.06.004 CuZn39Pb2

43 1 Piece Air chamber stud bolt MT184.10.06.005 9SMn28K

44 1 Piece Cylinder pipe MT184.10.06.006 X6CrNi18-10

45 1 Piece Cap nut DIN 1587-M12 CuZn39Pb3

46 1 Piece Drain plug MT184.10.06.007 CuZn39Pb2

47 1 Piece Membrane safety valve SV.01-065.7,5 F3000.4

Spike

48 2 Piece Straight flange G1“ MT184.10.06.010 EN-GJL-200

49 1 Piece Poppet valve body MT184.10.08.001

50 2 Piece Valve bridge MT184.10.06.008 X14CrMoS17

51 1 Piece Cylinder cover seal MT184.10.06.009 SBR/B-870M

Item Quantity


Comments



10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

52 2 Piece Flat washer ISO 7089 -8 8-A2


54 1 Piece Air chamber seal MT184.10.06.011 SBR/B-870M


PVC

56 2 Piece Stud bolt MT184.10.06.012 X17CrNi16-2


58 2 Piece Seal DIN 7603-A-13x18x1,5

PVC

59 4 Piece Valve seat seal MT184.10.06.014 SBR/B-870M

60 3 Piece Hexagon screw ISO 4017-M6x16 8.8-A2


62 2 Piece Seal MT184.10.06.015 SBR/B-870M

63 1 Piece Plain washer MT184.10.06.016 X17CrNi16-2


PVC

65 1 Piece Seal DIN 7603-A-39x49x2

EPDM

66 1 Piece Valve seat MT184.10.07.001 CuZn40Al2

67 1 Piece Seal in valve seat MT184.10.07.002 80 NBR 180

68 1 Piece Delivery side valve pin MT184.10.01.001 CuZn39Pb3

69 1 Piece Delivery side valve seat Mt184.10.01.002 CuZn39Pb3

70 1 Piece Valve rubber plate MT184.10.01.003 NBR-45° Shore A

71 1 Piece Hold-down MT184.10.01.004 CuZn39Pb3

72 1 Piece Intake side valve pin MT184.10.02.001 CuZn39Pb3

73 1 Piece Intake side valve seat MT184.10.02.002 CuZn39Pb3


Item Quantity


Comments



10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


76 1 Piece Hexagon nut ISO 10511.M6 A2


78 1 Piece Rocker shaft MT184.10.00.001 X14CrMoS17

79 1 Piece Rocker shaft with thread MT184.10.00.002 X14CrMoS17

80 4 Piece Insulating bush MT184.10.00.003 GP-22

81 1 Piece Motor clamp rail left MT184.10.00.004 EN-GJL-200

82 1 Piece Motor clamp rail right MT184.10.00.005 EN-GJL-200

83 1 Piece V-belt pulley MT184.10.00.006 EN-GJL-200



86 2 Piece Flat washer ISO 7089-A-8 140 HV

87 3 Piece Hexagon screw ISO 4017-M6x-10 8.8

88 1 Piece Valve housing complete MT184.00.06.000

89 1 Piece Crankcase complete MT184.00.09.000

90 1 Piece Intake valve complete MT184.00.01.000

91 1 Piece Pressure valve complete MT184.00.02.000

92 1 Piece Valve seat MT184.00.07.000

Item Quantity


Comments



10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5 Assembly and dismantling of the piston pump

5.1 Assembly of the piston pump

The piston pump assembly procedure is divided into eight phases:

• Assembly phase 1 – Crankshaft (assembly unit 1)

• Assembly phase 2 – Connecting rod with piston rod (assembly unit 2)

• Assembly phase 3 – Packing gland (assembly unit 3)

• Assembly phase 4 – Intake valve (assembly unit 4)

• Assembly phase 5 – Pressure valve (assembly unit 5)

• Assembly phase 6 – Gearbox (assembly unit 6)

• Assembly phase 7 – Pump housing (assembly unit 7)

• Assembly phase 8 – Pump

Tools:

• Puller

• Punch

• Wrench size 10 (2 x), size 13, size 14, size 19 and size 22

• Screwdriver

• Vice – not supplied

• Soft hammer

• Jig 1, 2, 3 and 4

5 Assembly and dismantling of the piston pump 59

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.1.1 Assembly phase 1 – Crankshaft (assembly unit 1)

Fig. 5.1 Drawing of the crankshaft (assembly unit 1)

Fig. 5.2 Crankshaft, fully assembled (assembly unit 1)

Item Name

3 Crankshaft

24 Grooved ball bearing


3 25 25 24


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Fig. 5.3 Parts required for assembly

Item Name

3 Crankshaft



3 25 25 24


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Procedure for assembling the crankshaft (assembly unit 1)

Grooved ball bearing(item 25)



Crankshaft(item 3)

Crankshaft(assembly unit 1)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Assembly procedure for crankshaft (assembly unit 1)

• Lightly oil crankshaft (3) to aid assembly of grooved ball bearings.

• Fit grooved ball bearing (25) onto crankshaft (3) and position at connectingrod seat.

• Using a soft hammer and jig 2, drive grooved ball bearing (25) ontocrankshaft, without bending it, until grooved ball bearing contacts recess.

• Fit grooved ball bearing (25) onto drive side of crankshaft (3).


Fig. 5.4 Assembling the grooved ball bearing with jig 2


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Fig. 5.5 Assembling the grooved ball bearing with jig 3


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.1.2 Assembly phase 2 – Connecting rod with piston rod (assembly unit 2)

Fig. 5.6 Drawing of connecting rod with piston rod (assembly unit 2)

Fig. 5.7 Connecting rod with piston rod, fully assembled (assembly unit 2)

Item Name Item Name

1 Connecting rod 29 Hexagon nut

26 Crosshead 30 Hexagon screw

27 Piston Rod 31 Hexagon nut

28 Straight pin

27 29 26 28 1 30, 31


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Name Item Name

1 Connecting rod 29 Hexagon nut

26 Crosshead 30 Hexagon screw

27 Piston Rod 31 Hexagon nut

28 Straight pin

29 26 28 31 30

27

1


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Procedure for assembling the connecting rod with piston rod (assembly unit 2)

Crosshead(item 26)

Straight pin(item 28)

Hexagon nut(item 29)

Connecting rod(item 1)

Connecting rod with piston rod

(assembly unit 2)

Piston rod(item 27)

Hexagon screw with hexagon nut

(item 30, 31)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Assembly procedure for connecting rod with piston rod (assembly unit2)

• Fit crosshead (26) onto connecting rod (1).

• Using a soft hammer and punch, carefully drive straight pin (28) into holein crosshead (26) and connecting rod (1).

• Screw hexagon nut (29) onto thread of piston rod (27).

• Screw piston rod with thread side onto which nut was screwed intocrosshead.

• Tighten hexagon nut against crosshead.

• Screw hexagon screw with hexagon nut (30, 31) into end of connectingrod.

Fig. 5.9 Assembling the crosshead with connecting rod


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.1.3 Assembly phase 3 – Packing gland (assembly unit 3)

Fig. 5.10 Drawing of the packing gland (assembly unit 3)

Fig. 5.11 Packing gland, fully assembled (assembly unit 3)

Item Name

2 Packing gland housing

32 Packing gland screw

33 Brass washer

34 Gland packing

35 Lip seal

35 32

33 2

34


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


32

332, 35

34

Item Name



33 Brass washer

34 Gland packing

35 Lip seal


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Procedure for assembling the packing gland (assembly unit 3)

Brass washer(item 33)

Packing gland packing(item 34)

Packing gland housing with lip seal(item 2, 35)

Packing gland(assembly unit 3)

Packing gland screw(item 32)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Assembly procedure for packing gland (assembly unit 3)

NOTICEThe lip seal (35) is not suitable for repeatedassembly and disassembly, as it would bedamaged. It is pre-assembled.

• Insert brass washer (33) into packing gland housing (2).

• Push four packing gland packs (34) into packing gland housing (2). Theabutment of each must be at a 90° offset.

• Screw packing gland screw (32) into packing gland housing.

Fig. 5.13 Inserting the packing gland packs


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.1.4 Assembly phase 4 – Intake valve (assembly unit 4)

Fig. 5.14 Drawing of the intake valve (assembly unit 4)

Fig. 5.15 Intake valve, fully assembled (assembly unit 4)

Item Name

72 Intake side valve pin

73 Intake side valve seat

74 Valve rubber plate

75 Hold-down

76 Hexagon nut

72

73

74

75

76


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Name




75 Hold-down

76 Hexagon nut

76 75

72, 73 74


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Procedure for assembling the intake valve (assembly unit 4)

Valve rubber plate(item 74)

Hold-down(item 75)

Intake side valve pin with intake side valve seat

(item 72, 73)

Intake valve(assembly unit 4)

Hexagon screw (item 76)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Assembly procedure for intake valve (assembly unit 4)

NOTICEThe intake side valve pin (72) is pre-assembledwith the intake side valve seat (73).

• Fit valve rubber plate (74) onto intake side valve pin (72) with curved sidefacing outwards.

• Fit hold-down (75) onto valve pin with cylindrical side first.

• Screw hexagon nut (76) onto valve pin.

• Carry out same assembly procedure for second intake valve.

Fig. 5.17 Assembling the hold-down


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.1.5 Assembly phase 5 – Pressure valve (assembly unit 5)

Fig. 5.18 Drawing of the pressure valve (assembly unit 5)

Fig. 5.19 Pressure valve, fully assembled (assembly unit 5)

Item Name

68 Delivery side valve pin

69 Delivery side valve seat


71 Hold-down

68

71

70

69


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Name




71 Hold-down

71 68

69 70


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Procedure for assembling the pressure valve (assembly unit 5)

Valve rubber plate(item 70)

Hold-down(item 71)

Delivery side valve seat(item 69)

Pressure valve(assembly unit 5)

Delivery side valve pin (item 68)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Assembly procedure for pressure valve (assembly unit 5)

• Place valve rubber plate (70) on ridged side of delivery side valve seat (69)with curved side facing outwards.

• Fit hold-down (71) with cylindrical side first into valve rubber plate (70).

• Fit delivery side valve pin (68) into holes in hold-down and valve seat.Carefully hammer valve pin into valve seat.

• Carry out same assembly procedure for second pressure valve.

Fig. 5.21 Assembling the delivery side valve pin


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.1.6 Assembly phase 6 – Gearbox (assembly unit 6)

Fig. 5.22 Drawing of the gearbox (assembly unit 6)

21, 22

11

6 4, 23

19

A

7 5 B 13 9 12 C 10 17 18

14


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Fig. 5.23 Parts list for gearbox (assembly unit 6)

Fig. 5.24 Gearbox, fully assembled (assembly unit 6)

Item Name Item Name

A Crankshaft(assembly unit 1)

11 Bearing cover seal

B Connecting rod with piston rod (assembly unit 2)

12 Oil stripper

C Packing gland(assembly unit 3)

13 Oil plug

4, 23 Bearing cover, open, with radial shaft seal

14 Duo-piston

5 Gearbox housing 17 Hexagon nut

6 Bearing cover, closed 18 Spring ring

7 Gearbox cover 19 Hexagon screw

9 Oil splash guard 21, 22 Angled oiler with nut and seal

10 Packing gland seal


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


A

B

C

6

7

9

10

11

12

13

14

17, 18

19

21, 22

4, 23

5

Item Name Item Name

A Crankshaft(assembly unit 1)


B Connecting rod with piston rod (assembly unit 2)

12 Oil stripper

C Packing gland(assembly unit 3)

13 Oil plug


14 Duo-piston

5 Gearbox housing 17 Hexagon nut

6 Bearing cover, closed 18 Spring ring

7 Gearbox cover 19 Hexagon screw

9 Oil splash guard 21, 22 Angled oiler with nut and seal



10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Procedure for assembling the gearbox (assembly unit 6)

Oil splash guard(item 9)

Connecting rod with piston rod (assembly

unit 2, item B)

Gearbox housing(item 5)

Oil stripper(item 12)

Packing gland seal(item 10)

Packing gland (assembly unit 3,

item C)

Crankshaft (assembly unit 1,

item A)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Bearing cover seal (item 11)

Hexagon screws (item 19)

Bearing cover seal(item 11)

Bearing cover, closed(item 6)

Hexagon screws(item 19)

Bearing cover seal (item 11)

Bearing cover, open, with radial shaft seal

(item 4, 23)

Hexagon screws (item 19)

Gearbox cover (item 7)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Hexagon nut(item 17)

Duo-piston(item 14)

Gearbox(assembly unit 5)

Spring ring with hexagon nut (item 18, 17)

Angled oiler with seal and nut

(item 21, 22)

Oil plug(item 13)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Assembly procedure for gearbox (assembly unit 6)

• Fit oil splash guard (9) into gearbox housing (5).

• Fit connecting rod with piston rod (B, assembly unit 2) into gearboxhousing (5). Do not yet insert crosshead into guide bush, leaving piston rodprotruding out of oil splash guard slightly.

• Push oil stripper (12) onto piston rod by twisting.

• Place packing gland seal (12) on packing gland (C, assembly unit 3).

• Slot piston rod through packing gland (C, assembly unit 3) and insertcrosshead in guide bush.

• Fit crankshaft (A, assembly unit 1) into connecting rod base. Use ascrewdriver to spread the connecting rod base so the connecting rodbearing can be easily inserted.

Fig. 5.26 Inserting the connecting rod with piston rod


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Place bearing cover seal (11) against gearbox housing.

• Attach closed bearing cover (6) to gearbox housing by hexagon screws(19).

NOTICEThe radial shaft seal (23) is not suitable forrepeated assembly and disassembly, as it wouldbe damaged. It is pre-assembled with the openbearing cover (4).

• Place bearing cover seal (11) against gearbox housing.

• Attach open bearing cover (4) to gearbox housing by hexagon screws (19).

Fig. 5.27 Assembling the crankshaft


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Tighten screw fitting on connecting rod.

• Mount gearbox cover (7) on gearbox housing.

• Screw hexagon nut (17) onto piston rod.

• Fit duo-piston (14) onto piston rod.

• Screw hexagon nut with spring ring (17, 18) against duo-piston (14).

• Screw angled oiler with seal and nut (item 21, 22) onto gearbox housing.

Fig. 5.28 Assembling the open bearing cover


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Insert oil plug (13).

Fig. 5.29 Assembling the angled oiler


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.1.7 Assembly phase 7 – Pump housing (assembly unit 7)

Fig. 5.30 Drawing of the pump housing (assembly unit 7)

42, 5

8

45 63 43 41

4060 59

51

50, 5

2, 5

3

B 59 39

65

47

4861

A

62

46, 7

7


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Fig. 5.31 Parts list for gearbox (assembly unit 6)

Fig. 5.32 Pump housing, fully assembled (assembly unit 7)

Item Name Item Name

D Assembly unit 4 49, 64 Poppet valve body with seal

E Assembly unit 4 50 Valve bridge

40 Cylinder cover 51 Cylinder cover seal

41 Air chamber 52 ,53 Hexagon nut with washer

42, 58 Water plug with seal 54 Air chamber seal

43 Air chamber stud bolt 59 Valve seat seal

45, 63 Cap nut with washer 60 Hexagon screws

46, 77 Drain plug with seal 61 Hexagon screws

47, 65 Membrane safety valve with seal 62 Seal

48 Straight flange G1“


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Name Item Name

D Intake valve (assembly unit 4) 48 Straight flange G1“

E Pressure valve (assembly unit 5) 49, 64 Poppet valve body with seal

39 Pump housing 50 Valve bridge

40 Cylinder cover 51 Cylinder cover seal

41 Air chamber 52, 53 Hexagon nut with washer

42, 58 Water plug with seal 54 Air chamber seal

43 Air chamber stud bolt 59 Valve seat seal

45, 63 Cap nut with washer 60 Hexagon screws

46, 77 Drain plug with seal 61 Hexagon screws

47, 65 Membrane safety valve with seal 62 Seal

D

E

40

41

42, 58

43

45, 63

47, 65

48

49, 64

5051 52, 53

54

59

60

61

62

39

46, 77


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Procedure for assembling the pump housing (assembly unit 7)

Valve seat seal(item 59)

Intake valve(assembly unit 4,

item D)

Pump housing(item 39)

Pressure valve(assembly unit 5,

item E)

Valve bridge (item 50)

Hexagon nut with washer(item 32, 53)

Drain plugwith seal

(item 46, 77)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Seal (item 62)

Straight flange(item 48)


Cylinder cover seal(item 51)

Cylinder cover(item 40)


Poppet valve body with seal

(item 49, 64)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Air chamber stud bolt (item 43)

Air chamber seal(item 54)

Pump housing(assembly unit 7)

Air chamber(item 41)

Cap nut with washer(item 45, 63)

Water plug with seal(item 42, 58)

Membrane safety valve with seal

(item 47, 65)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Assembly procedure for pump housing (assembly unit 7)

NOTICEThe cylinder pipe is pre-assembled in the pumphousing.

• Place valve seat seal (59) in pump housing (39).

• Place both intake valves (D, assembly unit 4) on one side in pump housing(39).

• Place both pressure valves (E, assembly unit ) on other side in pumphousing.

• Place a valve bridge (50) over each intake valve and pressure valve.

• Screw together valve bridges (50) with hexagon screw and washer (52,53) and already fitted stud bolts.

• Screw drain plug with seal (46, 77) into tapped hole.

Fig. 5.34 Inserting the intake valves and pressure valves in the pump housing


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Fit seals (62) at intake and pressure fittings.

• Screw both straight flanges (48) with hexagon screws (61) to intake andpressure fittings.

• Place cylinder cover seal (51) against pump housing.

• Screw cylinder cover (40) with hexagon screws (60) to pump housing.

• Screw poppet valve body with seal (49, 64) into cylinder cover.

• Screw air chamber bolt (43) into pump housing.

• Push air chamber seal (54) over air chamber bolt and place on housing.

Fig. 5.35 Assembling the cylinder cover


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Fit air chamber (41) onto pump housing. Opening for membrane safetyvalve must be above intake valves.

• Screw cap nut with washer (45, 63) onto air chamber bolt.

• Screw water plug with seal (42, 58) into air chamber.

• Screw membrane safety valve with seal (47, 65) into air chamber using jig1. The valve seat is pre-assembled.

Fig. 5.36 Inserting the air chamber seal

Fig. 5.37 Assembling the membrane safety valve


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.1.8 Assembly phase 8 – Pump

Fig. 5.38 Drawing of the pump (assembly unit 8)

Item Name Item Name

C Packing gland (assembly unit 3) 79 Rocker shaft with thread

F Gearbox (assembly unit 6) 81, 82 Motor clamp rails left and right

G Pump housing (assembly unit 7) 83 V-belt pulley

15 Disk spring 84 Hexagon screw

78 Rocker shaft 85, 86 Hexagon nut with washer

81, 82 79 84, 85 A 87 78 85, 86 C

1583, 87 B


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Fig. 5.39 Pump, fully assembled (assembly unit 8)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Name Item Name

F Gearbox (assembly unit 6) 81, 82 Motor clamp rails left and right

G Pump housing (assembly unit 7) 83 V-belt pulley

15 Disk spring 84 Hexagon screw

78 Rocker shaft 85, 86 Hexagon nut with washer

79 Rocker shaft with thread 87 Hexagon screw

G

F

157879

81, 82

83, 87

84, 85

87

85, 86


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Procedure for assembling the pump (assembly unit 8)

Pump housing (G, assembly unit 7)

Hexagon nut with washer(item 85, 86)

Gearbox (F, assembly unit 6)

Disk spring(item 15)

V-belt pulley with hexagon screw (item 83, 87)

Rocker shaft(item 78)

Motor clamp rails left and right

(item 81, 82)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Hexagon screw (item 87)

Rocker shaft with thread

(item 79)

Piston pump

Hexagon screw with hexagon nut

(item 84, 85)


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Assembly procedure for pump (assembly unit 8)

• Grease piston and insert carefully into cylinder pipe.

Then place pump housing (G, assembly unit 7) against Gearbox (F,assembly unit 6).

Screw together pump housing and gearbox with hexagon nut (85) and pre-assembled stud bolts.

• Fit packing gland (C, assembly unit 3) with hexagon nut and washer (85,86) on stud bolts.

• Place disk spring (15) with round side facing downwards into groove incrankshaft.

• Push V-belt pulley (83) with loosely fitted hexagon screw (87) over diskspring onto crankshaft and then tighten hexagon screw.

• Fit rocker shaft (78) into hole on gearbox housing.

Fig. 5.41 Fitted packing gland


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Slot left and right motor clamp rails (81, 82) with pre-assembled hexagonscrew side onto rocker shaft. The insulating bushes are pre-assembled inthe motor clamp rails.

• Fix rocker shaft with hexagon screw (87) on gearbox housing.

• Route rocker shaft with thread (79) into rear holes on motor clamp rails.

• Screw hexagon screw (84) into tapped hole of rocker shaft with thread (79)and lock with hexagon nut (85).

Fig. 5.42 Gearbox housing with rocker shafts and V-belt pulley

Fig. 5.43 Assembling the rocker shaft


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.2 Dismantling the piston pump

5.2.1 Dismantling assembly phase 8 – Pump

• Loosen hexagon nut (85) and unscrew hexagon screw (84) from tappedhole of rocker shaft with thread (79).

• Pull rocker shaft with thread (79) out of rear holes on motor clamp rails.

• Detach left and right motor clamp rails (81, 82) from rocker shaft. Theinsulating bushes remain fitted in the motor clamp rails.

• Unscrew hexagon screw (87) from gearbox housing

• Pull rocker shaft (78) out of hole in gearbox housing.

• Loosen hexagon screw (87) and detach V-belt pulley (83) from crankshaftover disk spring.

Fig. 5.44 Dismantling the rocker shaft


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Lever disk spring (15) out of groove on crankshaft with screwdriver.

• Unscrew hexagon nut and washer (85, 86) from stud bolts and detachpacking gland (C, assembly unit 3) from pump.

• Unscrew hexagon nut (85) from stud bolts and detach pump housing (G,assembly unit 7) from gearbox (F, assembly unit 6). Carefully guide pistonout of cylinder pipe when doing so.

Fig. 5.45 Dismantling the V-belt pulley

Fig. 5.46 Dismantling the pump housing


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Fig. 5.47 Piston pumps, dismantled into assembly units


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.2.2 Dismantling assembly phase 7 – Pump housing

• Unscrew membrane safety valve (47) from air chamber (41) using jig 1.Remove seal (65).

NOTICEThe valve seat of the membrane safety valveremains fitted.

• Unscrew water plug with seal (42, 58) from air chamber (41).

• Unscrew cap nut with washer (45, 63) from air chamber bolt (43).

• Lift air chamber (41) from pump housing (39).

• Pull air chamber seal (54) over air chamber bolt (43) and remove fromhousing.

• Unscrew air chamber bolt from pump housing (39).

• Unscrew poppet valve body with seal (49, 64) from cylinder cover (40).

Fig. 5.48 Removing the air chamber


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Loosen hexagon screws (60) and take cylinder cover (40) with cylindercover seal (51) from pump housing.

• Loosen hexagon screws (61) and remove both straight flanges (48) withseals (62) from intake and pressure fittings.

• Unscrew drain plug with seal (46, 77) from tapped hole in pump housing.

• Unscrew hexagon screws and washers (52, 53) from stud bolts on valvebridges (50).

• Lift valve bridges (50) from intake and pressure valves.

Fig. 5.49 Dismantling the poppet valve body

Fig. 5.50 Removing the intake and pressure valves


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Take pressure valve (E, assembly unit 5) out of pump housing.

• Take intake valve (D, assembly unit 4) out of pump housing.

• Remove valve seat seal (59) from pump housing.

NOTICEThe cylinder pipe remains fitted in the pumphousing.

Fig. 5.51 Pump housing, dismantled


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.2.3 Dismantling assembly phase 6 – Gearbox

• Remove oil plug (13).

• Unscrew angled oiler with seal and nut (item 21, 22) from gearbox housing(5).

• Unscrew hexagon nut with spring ring (17, 18) from duo-piston (14).

• Pull duo-piston (14) from piston rod (27).

• Unscrew hexagon nut (17) from piston rod (27).

• Lever gearbox cover (7) from gearbox housing (5).

• Unscrew hexagon screws (19) from gearbox housing and remove openbearing cover (4) with bearing cover seal (11) from gearbox housing.

NOTICEThe radial shaft seal (23) is not suitable forrepeated assembly and disassembly, as it wouldbe damaged. It remains fitted in the open bearingcover (4).

• Unscrew hexagon screws (19) from gearbox housing and remove closedbearing cover (6) with bearing cover seal (11) from gearbox housing.

Fig. 5.52 Detaching the duo-piston


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Loosen screw fitting on connecting rod.

• Pull crankshaft (A, assembly unit 1) out of connecting rod base. Use ascrewdriver to spread the connecting rod base so the connecting rodbearing can be easily removed.

• Pull piston rod out of packing gland (C, assembly unit 3) and crossheadout of guide bush. Leave connecting rod in gearbox housing.

Fig. 5.53 Loosening the connecting rod screw fitting

Fig. 5.54 Removing the packing gland


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

• Take packing gland seal (12) from packing gland (C, assembly unit 3).

• Pull oil stripper (12) from piston rod by twisting.

• Take connecting rod with piston rod (B, assembly unit 2) out of gearboxhousing (5).

• Lever oil splash guard (9) from gearbox housing (5).

Fig. 5.55 Gearbox, dismantled


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.2.4 Dismantling assembly phase 5 – Pressure valve

• Carefully hammer delivery side valve pin (68) out of delivery side valveseat (69).

• Pull valve pin out of hole in hold-down (71) and valve seat.

• Pull hold-down (71) out of valve rubber plate (70).

• Take valve rubber plate (70) from valve seat.

• Carry out same dismantling procedure for second pressure valve.

Fig. 5.56 Driving valve pin out of valve seat

Fig. 5.57 Pressure valve, disassembled


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.2.5 Dismantling assembly phase 4 – Intake valve

• Unscrew hexagon nut (76) from intake side valve pin (72).

• Pull hold-down (75) from intake side valve pin (73).

• Take valve rubber plate (74) from intake side valve pin (72).

• Intake side valve pin (72) remains assembled with intake side valve seat(73).

• Carry out same dismantling procedure for second intake valve.

Fig. 5.58 Removing the valve rubber plate

Fig. 5.59 Pressure valve, disassembled


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.2.6 Dismantling assembly phase 3 – Packing gland

• Unscrew packing gland screw (32) from packing gland housing (2).

• Drive packing gland packs (34) out of packing gland housing (2). Strike thebrass washer (33) with a punch to do so.

• Take brass washer (33) out of packing gland housing.

NOTICEThe lip seal (35) is not suitable for repeatedassembly and disassembly, as it would bedamaged. It remains fitted.

Fig. 5.60 Driving out the packing gland packs

Fig. 5.61 Packing gland, disassembled


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.2.7 Dismantling assembly phase 2 – Connecting rod with piston rod

• Unscrew hexagon screw with hexagon nut (30, 31) from end of connectingrod.

• Loosen hexagon nut (29) of crosshead and unscrew piston rod (27) fromcrosshead (26).

• Unscrew hexagon nut (29) from thread of piston rod (27).

• Using a soft hammer and punch, carefully drive straight pin (28) out of holein crosshead (26) and connecting rod (1).

• Take crosshead (26) from connecting rod (1).

Fig. 5.62 Driving out the straight pin

Fig. 5.63 Connecting rod, dismantled


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

5.2.8 Dismantling assembly phase 1 – Crankshaft

• Place puller over grooved ball bearing (24).

Press hook arms evenly onto grooved ball bearing.

Turn adjuster thread against shaft end. Ensure jig is centred.

Detach grooved ball bearing from crankshaft (3) by carefully turningadjuster thread.

• Pull grooved ball bearing (25) from crankshaft in same way using a puller.

• Place grooved ball bearing (25) with crankshaft on jig 4.

Drive the grooved ball bearing from the shaft by carefully hammering onthe shaft. Use jig 4 and an additional vice as braces.

Fig. 5.64 Pulling off the grooved ball bearing


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Fig. 5.65 Driving out the grooved ball bearing

Fig. 5.66 Crankshaft, dismantled


10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6 Tasks

Tasks / Exercises Topic

Worksheet 1 Introduction to the piston pump

Worksheet 2 Design, function and applications

Worksheet 3 Identifying causes of faults

Worksheet 4 Sealing systems

Worksheet 5 Inspection

Worksheet 6 Servicing

Worksheet 7 Repairs

Worksheet 8 Wearing parts

Worksheet 9 Assembly of the piston pump

Worksheet 10 Piston replacement

Worksheet 11 Parts identification using the spare parts drawing

Worksheet 12 Spare parts ordering

6 Tasks 122

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.1 Spare parts drawing and spare parts list


83, 8

7

81, 8

2

79, 8

084

, 85

8779

, 80

85, 8

6

8

6 Tasks 123

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


19

6

22

21

4, 23

16

11

3 - 15

8

20

10

3435 14

171833

2

321227913 29282657 1 30,31 24 25

6 Tasks 124

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


4245 63 43

4060

51

50, 5

2, 5

3

59

39

65

47

4861

7462

46, 7

776757372

4767

6658

41

54 68

69

7071

4457

58

3849

373664

6 Tasks 125

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Item Quantity


Comments






















PVC



NBR




6 Tasks 126

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8













38 1 Piece Cap MT184.10.08.004 NBR










Spike





Item Quantity


Comments


6 Tasks 127

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8





PVC




PVC







PVC


EPDM










Item Quantity


Comments


6 Tasks 128

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8



















Item Quantity


Comments


6 Tasks 129

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.2 Worksheet 1: Introduction to the piston pump, page 1

Objective:

To obtain an overview of the design and function of the piston pump.

Exercise:

You are provided with an assembled pump. Dismantle the pump so that allthe component parts are laid out before you.

6 Tasks 130

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 1, page 2

Pick up the pump drawings and the parts list. Locate the components in thedrawings. Refer to the parts list to find out the correct names of thecomponents.

6 Tasks 131

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 1, page 3

You are now familiar enough with the overall design of the pump to be ableto answer the following questions:

1. With what type of displacement device is the pump fitted?

2. Does a piston pump have a specific direction of rotation? Or are clockwiseand anti-clockwise both possible?

3. Can you explain the basic operating principle of a piston pump?

4. Look at the materials in the parts list. For which media could the pump besuitable?

6 Tasks 132

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.3 Worksheet 2: Design, function and applications of the piston pump, page 1

Objective:

To explain the design of the pump. To understand and describe its method ofoperation and usage.

Exercise:

1. Describe the design of the pump.

Use the drawings.

2. Name the five key components.

6 Tasks 133

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 2, page 2

3. Explain the method of operation of the pump. Explain the deliveryprinciple.

4. In what areas is the piston pump used?

6 Tasks 134

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.4 Worksheet 3: Identifying causes of faults, page 1

Objective:

To identify or suspect likely causes of faults in response to specificmalfunctions while the pump is operating.

Exercise:

Try to find the causes of the faults listed in the table below. Note down yourassumptions in the right-hand section of the table. You can exclude system-related disturbances.

Fault Suspected cause

Medium leaking from pump body

Running noise has markedly increased

The pressure difference usually generated between the inlet and outlet is no longer being attained

The pressure difference is much less than normal

The pump housing has a much higher surface temperature than normal

The current consumption of the drive motor has increased significantly compared to normal operating conditions

Service life of piston too short

6 Tasks 135

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.5 Worksheet 4: Sealing systems, page 1

Objective:

To divide sealing systems into basic categories and identify them based onthe example of the pistons.

Information: Sealing systems we can find in pumps are classified as follows:

Static seals

(seals subject to stationary stress)

Dynamic seals

(seals subject to motion)

Sealing systems

6 Tasks 136

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 4, page 2

Exercise:

1. Here you see the sectional drawing of the pump.

• In the sectional drawing, mark the static seals as S and the dynamicseals as D.

• What functions do the static and dynamic seals perform?

6 Tasks 137

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 4, page 3

When you have identified the sealing systems used in the piston pump, moveon to the following exercise.

2. Describe the design and method of operation of a shaft seal based on thefloating ring principle.

3. Look at a shaft seal based on the packing gland principle and describe it.

6 Tasks 138

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.6 Worksheet 5: Inspection of pumps, page 1

Objective:

To know what the term “inspection” involves, and to draw up an inspectionplan.

Exercise:

1. What does the term “inspection” mean in the context of technicalmaintenance?

Mark the statements you consider to be true or false in the Yes or Nocolumn of the following table as appropriate.

Activity Yes No

The current actual status of a pump is recorded and assessed

Components such as pistons or seals are replaced as a preventive maintenance measure

Shaft bearings are lubricated and couplings re-aligned

Entire pump units are replaced

An inspection is always carried out with the system stopped

During an inspection operating data of the pump system are measured (read) and entered in an inspection plan

An inspection can be seen as equivalent to preventive repair

Inspection is a routine operation in machinery and plant maintenance

6 Tasks 139

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 5, page 2

When you have established what the term “inspection” means, move on tothe following exercise.

2. Imagine we were talking about a vital piston pump in a domestic waterprocess. Let’s also assume that this pump is similar in design to the pumpfrom our MT 184 practice kit.

Draw up an inspection plan by mean of which an inspection can bedocumented.

Inspection plan

Pump: Inspected by:

Serial no.: Date:

Item Comments

6 Tasks 140

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.7 Worksheet 6: Servicing of pumps, page 1

Objective:

To know what is meant by the term “servicing”.

Exercise:

1. What does the term “servicing” mean in the context of technicalmaintenance?


Activity Yes No

Components such as pistons, rod seals and gaskets are replaced as a preventive maintenance measure

The object of servicing is to record and assess the current actual status of a pump

Servicing of a pump is a routine operation, carried out at predetermined intervals

A service is usually carried out with the system stopped

Servicing can be seen as equivalent to preventive repair

During a service, packing glands are repositioned, couplings adjusted or oil fillings changed for example


Servicing is always carried out when damage to a pump is identified

6 Tasks 141

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 6, page 2

When you have established what the term “servicing” means, move on to thefollowing exercise.

2. Do you think that routine servicing is useful and necessary for the pistonpump from our MT 184 practice kit?

Give reasons for your decision.

3. Let’s assume that two piston pumps with the classic differing shaft sealsare being used in a domestic water process.

What servicing operations need to be carried out on the packing gland typeshaft seal and on the floating ring seal type?

6 Tasks 142

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.8 Worksheet 7: Repairs to pumps, page 1

Objective:

To know what is meant by the term “repairs” in this context and to draw up apreventive maintenance plan.

Exercise:

1. What does the term “repairs” mean in the context of technicalmaintenance?


Activity Yes No

Repairs involve replacing well-used parts with new ones, for example pistons and seals

Repairs are carried out when damage has occurred to the pump

Repairs may also be carried out as routine and preventive maintenance measures to prevent damage and stoppages from occurring in the first place


Preventive maintenance can prevent a pump from failing

Repairs are normally carried out with the system stopped

If servicing is carried out on a regular basis, repairs are not needed

6 Tasks 143

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 7, page 2

When you have established what the term “repairs” means, move on to thefollowing exercise.

2. Let us assume that our piston pump represents an important assembly ina domestic water process. A failure of the pump would result in the entireline being shut down.

In view of this, the pump is inspected and serviced at regular intervals.

To achieve the most reliable operation possible, the plant managementdecides to carry out routine preventive repairs to the unit.

Draw up a repair order for carrying out and documenting the work.

Use the drawings.

Inspection order

Pump: Inspected by:

Serial no.: Date:

Procedure Comments/Status

Parts to be replaced:

Parts to be checked:

6 Tasks 144

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.9 Worksheet 8: Wearing parts on the piston pump, page 1

Objective:

To identify the wearing parts on the piston pump.

Exercise:

1. Mark the wearing parts on the pump drawing and name them by way ofexample.

6 Tasks 145

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 8, page 2

2. Of what material are the wearing parts of the piston pump made?

Enter the wearing parts from the previous page in the table with theirmaterial data or standard designations.

Wearing part Material

6 Tasks 146

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.10 Worksheet 9: Assembling the piston pump, page 1

Objective:

To structure the assembly process. To identify which assembly units andphases can be compiled.

Exercise:

You have laid out all the component parts of the piston pump in front of you.Your task is to assemble the pump.

To do this, first assembly individual assembly units. Then combine theassembly units to create the overall system in a sequence of assemblyphases.

1. Collect the components from which you can compile assembly units andphases. Name the assembly units and phases.

Use the drawings.

•

Item Name

6 Tasks 147

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 2

•

•

•

Item Name

Item Name

Item Name

6 Tasks 148

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 3

•

•

Item Name

Item Name

6 Tasks 149

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 4

•

Item Name

6 Tasks 150

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 5

2. When you have put together the various assembly units, the next step isto assemble the pump.

You should carry out this phase and represent it in a structurecorresponding to the pattern shown.

Set out the identified assembly phases through to the complete pump.

Parts x, y, ...

Parts x, y, ...

Gearing

Piston pump

6 Tasks 151

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 6

Procedure for assembling the piston pump


Piston pump

6 Tasks 152

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.11 Worksheet 10: Piston replacement, page 1

Objective:

Planning and execution of piston replacement on a piston pump.

Exercise:

1. Your task is to replace the piston on a piston pump.

Set out your method in the pre-compiled work plan. Use the drawings.

6 Tasks 153

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 10, page 2

Work plan

Name: Piston pump – Piston replacement

Date: Carried out by:

Order no.: Date:

Procedure

Procedure Tools

Dismantling

Assembly

Estimated time required: ____ min

6 Tasks 154

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1

Objective:

To assign items from a spare parts list to a spare parts drawing.

Exercise:

You are given a spare parts drawing on which the item numbers have not yetbeen entered. Refer to the supplied spare parts list.

Enter the item numbers from the 1st column of the spare parts list in the fieldsin the spare parts drawing.

6 Tasks 155

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8



6 Tasks 156

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8



6 Tasks 157

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8



6 Tasks 158

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Quantity


Comments






















PVC



NBR




6 Tasks 159

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Quantity


Comments













38 1 Piece Cap MT184.10.08.004 NBR










Spike





6 Tasks 160

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Quantity


Comments






PVC




PVC







PVC


EPDM










6 Tasks 161

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Quantity


Comments





















6 Tasks 162

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

6.13 Worksheet 12: Spare parts ordering, page 1

Objective:

To place a technically unambiguous spare parts order.

Exercise:

You are going to carry out a repair, and need replacement parts for yourpiston pump.

Select three parts and make a spare parts order.

Use the documents provided.

Spare parts order for pump:

Parts:

6 Tasks 163

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7 Solutions

Tasks / Exercises Topic

Worksheet 1 Introduction to the piston pump

Worksheet 2 Design, function and applications

Worksheet 3 Identifying causes of faults

Worksheet 4 Sealing systems

Worksheet 5 Inspection

Worksheet 6 Servicing

Worksheet 7 Repairs

Worksheet 8 Wearing parts

Worksheet 9 Assembly of the piston pump

Worksheet 10 Piston replacement

Worksheet 11 Parts identification using the spare parts drawing

Worksheet 12 Spare parts ordering

7 Solutions 164

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.1 Spare parts drawing and spare parts list


83, 8

7

81, 8

2

79, 8

084

, 85

8779

, 80

85, 8

6

8

7 Solutions 165

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


19

6

22

21

4, 23

16

11

3 - 15

8

20

10

3435 14

171833

2

321227913 29282657 1 30,31 24 25

7 Solutions 166

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


4245 63 43

4060

51

50, 5

2, 5

3

59

39

65

47

4861

7462

46, 7

776757372

4767

6658

41

54 68

69

7071

4457

58

3849

373664

7 Solutions 167

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Item Quantity


Comments






















PVC



NBR




7 Solutions 168

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8













38 1 Piece Cap MT184.10.08.004 NBR










Spike





Item Quantity


Comments


7 Solutions 169

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8





PVC




PVC







PVC


EPDM










Item Quantity


Comments


7 Solutions 170

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8



















Item Quantity


Comments


7 Solutions 171

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.2 Worksheet 1: Introduction to the piston pump, page 1

Objective:

To obtain an overview of the design and function of the piston pump.

Exercise:

You are provided with an assembled pump. Dismantle the pump so that allthe component parts are laid out before you.

7 Solutions 172

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 1, page 2

Pick up the pump drawings and the parts list. Locate the components in thedrawings. Refer to the parts list to find out the correct names of thecomponents.

7 Solutions 173

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 1, page 3

You are now familiar enough with the overall design of the pump to be ableto answer the following questions:

1. With what type of displacement device is the pump fitted?

With a dual sleeved piston.

2. Does a piston pump have a specific direction of rotation? Or are clockwiseand anti-clockwise both possible?

The pump delivery is independent of the direction of rotation of the drive.However, optimum lubrication of the gearbox can only be effected in thedirection indicated by the arrow on the pump.

3. Can you explain the basic operating principle of a piston pump?

The enlargement of the delivery chamber creates a negative pressure andthe pumped liquid is drawn in via the intake valve. The subsequentreversal of stroke reduces the size of the pump chamber and the pistondisplaces the liquid by way of the pressure valve.

4. Look at the materials in the parts list. For which media could the pump besuitable?

Because of the materials used in it, the piston pump is used in particularto pump non-aggressive, fluid media, such as drinking water and domesticwater.

7 Solutions 174

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.3 Worksheet 2: Design, function and applications of the piston pump, page 1

Objective:

To explain the design of the pump. To understand and describe its method ofoperation and usage.

Exercise:

1. Describe the design of the pump.

Use the drawings.

The motor is mounted on the pump unit by clamp rails.

The crankshaft, the connecting rod and the crosshead are automaticallylubricated in the gearbox housing by circulating oil on every rotation.

The piston rod is sealed off from the delivery chamber by a packing gland.

The sleeved pistons made of NBR rubber run in a stainless steel cylinderbushing.

The two delivery chambers each contain two disk valves with valve rubberplates.

The delivery side of the pump is executed as an air chamber with a built-in safety valve.

2. Name the five key components.

Pump housing, gearbox housing, valves, piston, packing gland.

7 Solutions 175

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 2, page 2

3. Explain the method of operation of the pump. Explain the deliveryprinciple.

On every revolution, the crankshaft acts by way of the connecting rod andthe crosshead on the piston, which is mounted on the end of the piston rod.This stroke motion causes the piston to move back and forth in the cylinderbushing.

On every stroke the piston enlarges and reduces the size of the deliverychamber. In the enlarging delivery chamber a negative pressure iscreated, causing the pressure valve to close and liquid to flow via theintake valve into the delivery chamber. In the reducing delivery chamberthe piston presses the liquid via the pressure valve out of the pump body,while at the same time the intake valve is pressed closed.

4. In what areas is the piston pump used?

Piston pumps are used primarily to transport fluids at high deliverypressures and low flow rates.

Typical applications include pumping drinking water and domestic water inresidential areas, in agriculture, onboard ships, in industry and atcommercial garden centres.

7 Solutions 176

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.4 Worksheet 3: Identifying causes of faults, page 1

Objective:

To identify or suspect likely causes of faults in response to specificmalfunctions while the pump is operating.

Exercise:

Try to find the causes of the faults listed in the table below. Note down yourassumptions in the right-hand section of the table. You can exclude system-related disturbances.

Fault Suspected cause

Medium leaking from pump body Packing gland worn

Housing seals defective

Running noise has markedly increased Bearing damaged

Crankshaft or piston rod deformed

Oil filling too low

The pressure difference usually generated between the inlet and outlet is no longer being attained

The pressure difference is much less than normal

Pump valves leaking

Foreign bodies in the pump

Piston worn

The pump housing has a much higher surface temperature than normal

Crankshaft, bearing and crosshead damaged

Oil filling too low

The current consumption of the drive motor has increased significantly compared to normal operating conditions

Motor defective

Gearbox components defective

Service life of piston too short Foreign bodies in the pump

Dry running

Inadequate material resistance

7 Solutions 177

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.5 Worksheet 4: Sealing systems, page 1

Objective:

To divide sealing systems into basic categories and identify them based onthe example of the pistons.

Information: Sealing systems we can find in pumps are classified as follows:

Static seals

(seals subject to stationary stress)

Dynamic seals

(seals subject to motion)

Sealing systems

7 Solutions 178

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 4, page 2

Exercise:

1. Here you see the sectional drawing of the pump.

• In the sectional drawing, mark the static seals as S and the dynamicseals as D.

• What functions do the static and dynamic seals perform?

The static seals seal the housing.

The dynamic seals seal moving parts.

S

D

7 Solutions 179

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 4, page 3

When you have identified the sealing systems used in the piston pump, moveon to the following exercise.

2. Describe the design and method of operation of a shaft seal based on thefloating ring principle.

Floating ring seals are contact seals which create a yielding sealconnection between stationary and rotating contact faces. There is a filmof liquid between these contact surfaces. The film of liquid assumes astable position due to the centrifugal force occurring during rotation.

Static elastomer seals seal the floating ring seal from the housing. Therotating floating ring is held axially to the counter ring by a spring, which isfixed in the housing.

3. Look at a shaft seal based on the packing gland principle and describe it.

The gland packing is a woven cord mainly made of solid fabrics. It isdeformed in the packing space between the shaft and the housing by anaxial force and so pressed onto the surfaces being sealed.

A sleeve is fitted to protect the shaft. Locking rings or ancillary glands holdthe packing in place. The gland press compresses the packing by way ofscrew fittings.

7 Solutions 180

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.6 Worksheet 5: Inspection of pumps, page 1

Objective:

To know what the term “inspection” involves, and to draw up an inspectionplan.

Exercise:

1. What does the term “inspection” mean in the context of technicalmaintenance?


Activity Yes No

The current actual status of a pump is recorded and assessed X

Components such as pistons or seals are replaced as a preventive maintenance measure

X

Shaft bearings are lubricated and couplings re-aligned X

Entire pump units are replaced X

An inspection is always carried out with the system stopped X

During an inspection operating data of the pump system are measured (read) and entered in an inspection plan

X

An inspection can be seen as equivalent to preventive repair X

Inspection is a routine operation in machinery and plant maintenance X

7 Solutions 181

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 5, page 2

When you have established what the term “inspection” means, move on tothe following exercise.

2. Imagine we were talking about a vital piston pump in a domestic waterprocess. Let’s also assume that this pump is similar in design to the pumpfrom our MT 184 practice kit.

Draw up an inspection plan by mean of which an inspection can bedocumented.

Inspection plan

Pump: Inspected by:

Serial no.: Date:

Item Comments

Pump capacity

Delivery pressure

Leakage

Noise

Smooth running

Temperature

General condition

Oil level

7 Solutions 182

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.7 Worksheet 6: Servicing of pumps, page 1

Objective:

To know what is meant by the term “servicing”.

Exercise:

1. What does the term “servicing” mean in the context of technicalmaintenance?


Activity Yes No

Components such as pistons, rod seals and gaskets are replaced as a preventive maintenance measure

X

The object of servicing is to record and assess the current actual status of a pump

X

Servicing of a pump is a routine operation, carried out at predetermined intervals

X

A service is usually carried out with the system stopped X

Servicing can be seen as equivalent to preventive repair X

During a service, packing glands are repositioned, couplings adjusted or oil fillings changed for example

X


Servicing is always carried out when damage to a pump is identified

X

7 Solutions 183

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 6, page 2

When you have established what the term “servicing” means, move on to thefollowing exercise.

2. Do you think that routine servicing is useful and necessary for the pistonpump from our MT 184 practice kit?

Give reasons for your decision.

Yes! During servicing, the condition of the wearing parts is checked andthe parts are replaced as necessary. For the piston pump from MT 184 theparts are the piston, the housing seals, the valves, the packing gland andthe oil filling of the main gearbox.

3. Let’s assume that two piston pumps with the classic differing shaft sealsare being used in a domestic water process.

What servicing operations need to be carried out on the packing gland typeshaft seal and on the floating ring seal type?

Packing glands must be repositioned depending on the leakage rate. Theirgeneral condition must be checked and they must be repacked asnecessary.

Floating ring seals do not have to be adjusted. However, at each servicethe condition should be checked and, depending on the importance,replaced as a preventive measure.

7 Solutions 184

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.8 Worksheet 7: Repairs to pumps, page 1

Objective:

To know what is meant by the term “repairs” in this context and to draw up apreventive maintenance plan.

Exercise:

1. What does the term “repairs” mean in the context of technicalmaintenance?


Activity Yes No

Repairs involve replacing well-used parts with new ones, for example pistons and seals

X

Repairs are carried out when damage has occurred to the pump X

Repairs may also be carried out as routine and preventive maintenance measures to prevent damage and stoppages from occurring in the first place

X


Preventive maintenance can prevent a pump from failing X

Repairs are normally carried out with the system stopped X

If servicing is carried out on a regular basis, repairs are not needed X

7 Solutions 185

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 7, page 2

When you have established what the term “repairs” means, move on to thefollowing exercise.

2. Let us assume that our piston pump represents an important assembly ina domestic water process. A failure of the pump would result in the entireline being shut down.

In view of this, the pump is inspected and serviced at regular intervals.

To achieve the most reliable operation possible, the plant managementdecides to carry out routine preventive repairs to the unit.

Draw up a repair order for carrying out and documenting the work.

Use the drawings.

Inspection order

Pump: Inspected by:

Serial no.: Date:

Procedure Comments/Status

Parts to be replaced:

Valve rubber plate (70, 74)

Valve seat seal (59)

Air chamber seal (54)

Connection seals (62)

Cylinder cover seals (51)

Piston (14)

Packing gland packs (34)

Lip seal (35)

Oil filling

Parts to be checked:

Housing components

Bearings

Piston Rod

7 Solutions 186

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.9 Worksheet 8: Wearing parts on the piston pump, page 1

Objective:

To identify the wearing parts on the piston pump.

Exercise:

1. Mark the wearing parts on the pump drawing and name them by way ofexample.

Air chamber seal Cylinder seal Connection seal Valve seat seal

Glandpacking

Lip seal Piston Valve rubber plate

7 Solutions 187

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 8, page 2

2. Of what material are the wearing parts of the piston pump made?

Enter the wearing parts from the previous page in the table with theirmaterial data or standard designations.

Wearing part Material

Gland packing PTFE-saturated

Lip seal A2 - 70

Piston NBR

Valve rubber plate NBR-45° Shore A

Air chamber seal, cylinder seal, connection seal, valve seat seal

SBR/B-870M

7 Solutions 188

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.10 Worksheet 9: Assembling the piston pump, page 1

Objective:

To structure the assembly process. To identify which assembly units andphases can be compiled.

Exercise:

You have laid out all the component parts of the piston pump in front of you.Your task is to assemble the pump.

To do this, first assembly individual assembly units. Then combine theassembly units to create the overall system in a sequence of assemblyphases.

1. Collect the components from which you can compile assembly units andphases. Name the assembly units and phases.

Use the drawings.

• Assembly unit 1 – Crankshaft

Item Name

3 Crankshaft



7 Solutions 189

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 2

• Assembly unit 2 – Connecting rod with piston rod

• Assembly unit 3 – Packing gland

• Assembly unit 4 – Intake valve

Item Name

1 Connecting rod

26 Crosshead

27 Piston Rod

28 Straight pin

29 Hexagon nut

30 Hexagon screw

31 Hexagon nut

Item Name



33 Brass washer

34 Gland packing

35 Lip seal

Item Name




75 Hold-down

76 Hexagon nut

7 Solutions 190

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 3

• Assembly unit 5 – Pressure valve

• Assembly unit 6 – Gearbox

Item Name




71 Hold-down

Item Name

A Assembly unit 1

B Assembly unit 2

C Assembly unit 3

5 Gearbox housing

6 Bearing cover, closed

7 Gearbox cover

9 Oil splash guard



12 Oil stripper

13 Oil plug

14 Duo-piston

17 Hexagon nut

18 Spring ring

19 Hexagon screw

21, 22 Angled oiler with nut and seal


7 Solutions 191

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 4

• Assembly unit 7 – Pump housing

Item Name

D Assembly unit 4

E Assembly unit 5

40 Cylinder cover

41 Air chamber

42, 58 Water plug with seal

43 Air chamber stud bolt

54 Air chamber seal

59 Valve seat seal

60 Hexagon screws

61 Hexagon screws

62 Seal

45, 63 Cap nut with washer

46, 77 Drain plug with seal

47, 65 Membrane safety valve with seal

48 Straight flange G1“

49, 64 Poppet valve body with seal

50 Valve bridge

51 Cylinder cover seal

52, 53 Hexagon nut with washer

7 Solutions 192

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 5

2. When you have put together the various assembly units, the next step isto assemble the pump.

You should carry out this phase and represent it in a structurecorresponding to the pattern shown.

Set out the identified assembly phases through to the complete pump.

Parts x, y, ...

Parts x, y, ...

Gearing

Piston pump

7 Solutions 193

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Worksheet 9, page 6

Procedure for assembling the piston pump

Pump housing(assembly unit 7)

Hexagon nutwith washer(item 85, 86)


Disk spring(item 15)

V-belt pulley withhexagon screw(item 83, 87)

Rocker shaft(item 78)

Hexagon screwitem 87

Motor clamp railleft and right(item 81, 82)

Rocker shaftwith gearbox

(item 79)

Piston pump

Hexagon screwwith hexagon nut

(item 84, 85)

7 Solutions 194

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.11 Worksheet 10: Piston replacement, page 1

Objective:

Planning and execution of piston replacement on a piston pump.

Exercise:

1. Your task is to replace the piston on a piston pump.

Set out your method in the pre-compiled work plan. Use the drawings.

7 Solutions 195

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Work plan

Name: Piston pump – Piston replacement

Date: Carried out by:

Order no.: Date:

Procedure

Procedure Tools

Dismantling

1 Unscrew hexagon nut and washer (85, 86) from stud bolts and detach packing gland (assembly unit 3) from pump

Wrench size 13

2 Unscrew hexagon nut (85) from stud bolts Wrench size 13

3 Pull pump housing (assembly unit 7) from gearbox (assembly unit 6). Carefully guide piston out of cylinder pipe when doing so

4 Unscrew hexagon nut with spring ring (17, 18) from duo-piston (14)

Wrench size 13

5 Pull duo-piston from piston rod (27)

Assembly

6 Fit duo-piston onto piston rod

7 Screw hexagon nut with spring ring (17, 18) against duo-piston

Wrench size 13

8 Grease piston

Place pump housing (assembly unit 7) against gearbox (assembly unit 6). Carefully guide piston into cylinder pipe when doing so

9 Screw together pump housing and gearbox with hexagon nut (85) and pre-assembled stud bolts

Wrench size 13

10 Fit packing gland (assembly unit 3) with hexagon nut and washer (85, 86) on stud bolts

Wrench size 13

Estimated time required: 20 min

7 Solutions 196

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.12 Worksheet 11: Parts identification using the parts drawing, familiarisation with technical terms, page 1

Objective:

To assign items from a spare parts list to a spare parts drawing.

Exercise:

You are given a spare parts drawing on which the item numbers have not yetbeen entered. Refer to the supplied spare parts list.

Enter the item numbers from the 1st column of the spare parts list in the fieldsin the spare parts drawing.

7 Solutions 197

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8



83, 8

7

81, 8

2

79, 8

084

, 85

8779

, 80

85, 8

6

8

7 Solutions 198

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8



19

6

22

21

4, 23

16

11

3 - 15

8

20

10

3435 14

171833

2

321227913 29282657 1 30,31 24 25

7 Solutions 199

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8



4245 63 43

4060

51

50, 5

2, 5

3

59

39

65

47

4861

7462

46, 7

776757372

4767

6658

41

54 68

69

7071

4457

58

3849

373664

7 Solutions 200

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Quantity


Comments






















PVC



NBR




7 Solutions 201

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Quantity


Comments













38 1 Piece Cap MT184.10.08.004 NBR










Spike





7 Solutions 202

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Quantity


Comments






PVC




PVC







PVC


EPDM










7 Solutions 203

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8


Item Quantity


Comments





















7 Solutions 204

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

7.13 Worksheet 12: Spare parts ordering, page 1

Objective:

To place a technically unambiguous spare parts order.

Exercise:

You are going to carry out a repair, and need replacement parts for yourpiston pump.

Select three parts and make a spare parts order.

Use the documents provided.

Spare parts order for pump:

Type: PM 10

Serial no.:

Parts:

1 x duo-piston Item 14

4 x valve rubber plate Item 70

1 set of gland packs Item 34

7 Solutions 205

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

8 Index

A

Assembly phase 1 – Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 120Assembly phase 2 – Connecting rod with piston rod . . . . . . . . . . 65, 119Assembly phase 3 – Packing gland . . . . . . . . . . . . . . . . . . . . . . . 69, 118Assembly phase 4 – Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . 73, 117Assembly phase 5 – Pressure valve . . . . . . . . . . . . . . . . . . . . . . . 77, 116Assembly phase 6 – Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81, 113Assembly phase 7 – Pump housing . . . . . . . . . . . . . . . . . . . . . . . 91, 110Assembly phase 8 – Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 107

C

Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 8, 29Centrifugal pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29Characteristic curve, pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Characteristic curve, system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

D

Diaphragm pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 11, 30Dynamic seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

F

Floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

G

Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14, 32

H

Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

I

Inline centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 13, 31Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Intake characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8 Index 206

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

M

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Multi-flow pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Multiple-stage pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Multi-stage centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29

O

Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

P

Packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Parallel configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 12, 31, 46, 59Piston pump dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Piston pump spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Piston pump spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Piston rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 41Piston seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Positive-displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14Pump characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pump, multi-flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

R

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 34Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

S

Screw pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 10, 30Seals, dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Seals, floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Seals, packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 49Seals, static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Series configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Standard centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34System characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 Index 207

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

T

Technical data of piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

V

Valves in pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8 Index 208

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

9 Drawings

Name Drawing number

Layout MT184.00.00.000

Spare parts list MT184.00.00.000

Piston pump – Drawing MT184.00.00.000

Piston pump – Parts list MT184.00.00.000

Pressure valve, complete – Drawing MT184.00.01.000

Pressure valve, complete – Parts list MT184.00.01.000

Intake valve, complete – Drawing MT184.00.02.000

Intake valve, complete – Parts list MT184.00.02.000

Crankshaft with bearing – Drawing MT184.00.03.000

Crankshaft with bearing – Parts list MT184.00.03.000

Connecting rod with piston – Drawing MT184.00.04.000

Connecting rod with piston – Parts list MT184.00.04.000

Packing gland complete – Drawing MT184.00.05.000

Packing gland complete – Parts list MT184.00.05.000

Valve housing complete – Drawing MT184.00.06.000

Valve housing complete – Parts list MT184.00.06.000

Seat valve – Drawing MT184.00.07.000

Seat valve – Parts list MT184.00.07.000

Poppet valve – Drawing MT184.00.08.000

Poppet valve – Parts list MT184.00.08.000

Crankcase, complete – Drawing MT184.00.09.000

Crankcase, complete – Parts list MT184.00.09.000

Flange with seal – Drawing MT184.00.10.000

Flange with seal – Parts list MT184.00.10.000

Rocker shaft MT184.10.00.001

Rocker shaft with thread MT184.10.00.002

Insulating bush for motor rockers MT184.10.00.003

9 Drawings 209

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Motor clamp rail left MT184.10.00.004

Motor clamp rail right MT184.10.00.005

Pump V-belt rail MT184.10.00.006

Delivery side valve pin MT184.10.01.001

Delivery side valve seat MT184.10.01.002

Valve rubber plate MT184.10.01.003

Hold-down MT184.10.01.004

Intake side valve pin MT184.10.02.001

Crankshaft MT184.10.03.001

Connecting rod MT184.10.04.001

Crosshead MT184.10.04.002

Piston Rod MT184.10.04.003

Packing gland housing MT184.10.05.001

Packing gland screw MT184.10.05.002

Brass washer MT184.10.05.003

Valve housing MT184.10.06.001

Cylinder cover MT184.10.06.002

Air chamber MT184.10.06.003

Water plug MT184.10.06.004

Air chamber stud bolt MT184.10.06.005

Cylinder pipe MT184.10.06.006

Oil plug MT184.10.06.007

Valve bridge MT184.10.06.008

Cylinder cover seal MT184.10.06.009

Straight flange G1“ MT184.10.06.010

Air chamber seal MT184.10.06.011

Stud bolt MT184.10.06.012

Stud bolt MT184.10.06.013

Name Drawing number

9 Drawings 210

10/2008


All

right

s re

serv

ed, G

.U.N

.T. G

erät

ebau

, Bar

sbüt

tel,

Ger

man

y 10

/200

8

Valve seat seal MT184.10.06.014

Flange seal MT184.10.06.015

Plain washer MT184.10.06.016

Valve seat MT184.10.07.001

Seal in safety valve seat MT184.10.07.002

Poppet valve body MT184.10.08.001

Lock nut for poppet valve MT184.10.08.002

Knurled screw for poppet valve MT184.10.08.003

Cap MT184.10.08.004

Drive frame MT184.10.09.001

Bearing cover, closed MT184.10.09.002

Gearbox cover MT184.10.09.003

Base plate MT184.10.09.004

Oil splash guard MT184.10.09.005

Seal for packing gland MT184.10.09.006

Bearing cover seal MT184.10.09.007

Oil stripper MT184.10.09.008

Oil plug without thread MT184.10.09.009

Bearing cover, open MT184.10.10.001

Name Drawing number

9 Drawings 211

Documents

MT184CP