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CAUTION

This instruction manual has been prepared, to serve as a general guide in operating

and maintaining boiler and auxiliary equipment furnished by Powerhouse Equipment.It is intended for use by qualified personnel with knowledge of boilers and theiroperations. It is not intended to cover all possible variations in equipment nor toprovide for specific operating problems which may arise.

PLEASE NOTE: Should any question with regard to operation of the boiler and/orauxiliary equipment arise, Powerhouse Equipment or its Field Representative should becontacted immediately.

It must be recognized that no amount of written instruction can replace intelligent

thinking and reasoning on the part of the boiler operators. This manual is notintended to relieve the operating personnel of the responsibility for proper operation ofthe equipment. It is solely the operators responsibility to properly maintain theequipment. Personnel should become thoroughly familiar with the equipment beforeoperating or maintaining the equipment.

The companys liability for the equipment furnished is as set forth in the contract. Thecompany does not assume nor has it any responsibility for any equipment notfurnished by the company. No employee of the company is authorized to assume any

responsibility for equipment not furnished by the company.Competent supervision of mechanical and electrical equipment in burner and controlsis necessary to maintain safe and reliable operation.

In order to maintain these advantages, the manufacturers of packaged steamgenerators recognize that adequate supervisory maintenance is necessary and thatautomatic operation of these units does not eliminate the need for employing qualifiedoperators.

Manuals are prepared by Powerhouse Equipment and the cost of each manual isapproximately $600.00.

Donald R. Worthington Gerhard Debye-SaxingerEngineering Supervisor Fleet Supervisor

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WARRICKC

ONDUCTIVITYSENSORS

www.gemssensors.com D-24

14-5/8REF.

7-1/4REF.

XX3C X

Series3C

Number of Probes1 One2 Two

Body MaterialA Cast Iron

Length of Probes(specify length a suffix will be added by factory)

B Red Brass

3 Three4 Four

XX3K X X

Series3K

Number of Probes1 One2 Two

Tricock TappingsNPTA NoneB 1/2 NPTC 3/4 NPTD 1/2 NPT

E 3/4 NPTNPT Size

Gauge1 None2 None3 1/2 NPT4 1/2 NPT5 3/4 NPT6 3/4 NPT

Length of Probes(specify length a suffix will be added by factory)

Location1

NoneLeftLeftRight

Right

Equalizer1 NPT1-1/4 NPT1 NPT1 NPT1 NPT1-1/4 NPT

3 Three4 Four

Series 3C Short External Mount Side Chamber

Series 3K Long External Mount Side Chamber

Side Mounting Tricock Tappings

Gauge Tappings 1-4 Probes

Pressure Tight Cast Iron and Brass CSA Approved .L. Recognized

FM Approved

Series 3C side chamber ttings are cast iron or brass, pressure-tightchambers containing up to 4 probes from 1-1/2 to 6 in length.Pipe tappings provide connection to the side of boilers and pressurevessels to equalize the level in the chamber with the level in the vessel.

Series 3K ttings contain up to 4 probes and accommodate probesfrom 1-3/4 to 13 in length. Additional tappings are available fortricocks and gauges.

Specifcations

Probes 1 thru 4, with 316 Stainless Steel/Teon wetted parts

Body Materialeries 3C ast iron, red brass

eries 3K ast iron

Pressure/Temperature 50 psig @ 406F (saturated steam)

Probe Lengtheries 3C 1-1/2 to 6 (3.81 cm to 15.24 cm)

eries 3K 1-3/4 to 13 (4.45 cm to 33.02 cm)

Approvals U.L. File # MP2489, Vol. 1, Sec. 2; CSA; FM

How to Order Series 3CUse the Bold haracters from the chart below toconstruct a product code.

Notes:. onac your represen a ve or more e a s on s ng.

2. The 3C attaches to a vessel by two 1 NPT tappings, one1 NPT blowdown port and one 3/4 NPT side port.

eries 3C

eries 3K

ApplicationsBoilers

Hydropneumatic Tanks

Steam Generators

Pressure Vessels

Pump Operation

Low Water / High Water Alarm

How to Order Series 3KUse the Bold characters from the chart below toonstruct a product code.

Note:. ewer ac ng gauge g ass

FITTINGS AND PROBES

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61

BOILER

CONTROLS

BOILER CONTROLS

BOILER

CONTROLS

Model A B C D E F G H J K

NPT NPT NPT NPT NPT NPT NPT NPT NPT NPT

194 114 12 12 12 12 12 12 34

194-A 114 12 12 12 12 12 12 34

194-B 114 34 34 34 34 34 12 34

Model T U V W X Y

194 1714(438) 2012(521) 3 (76) 3 (76) 6 (152) 101316(274)

194-A 1714(438) 2012(521) 3 (76) 3 (76) 6 (152) 101316(274)

194-B 1714(438) 2012(521) 3 (76) 3 (76) 6 (152) 101316(274)

Model L M N P Q R S

194 1158(295) 634(171.4) 13116(332) 21316(71) 114(32) 238(60)

194-A 12

7

8(327) 63

4(171.4) 131

16(332) 213

16(71) 11

4(32) 23

8(60)194-B 1278(327) 634(171.4) 13116(332) 21316(71) 114(32) 238(60)

For commercial, and industrial low or high pressure

steam boilers Maintains consistent water level regardless of pressure

For boilers of any steaming capacity

Water column with integral tappings for gauge glass andtri-cock installations

No. 5 Switch included

Magnetic repulsion eliminates need for bellows

Optional featuresManual resetNo. 7-B On/Off or proportional control switch to

maintain constant boiler water level

114" NPT connections

Maximum pressure 250 psi (17.6 kg/cm2)

SERIES 194

B

K

JA

F

A

H

E

G

CUT-OFF LEVEL

250

X

N N

P

M

L

U

T

Q

S

R

V

W

C D

CUT-OFF

LEVEL

Low Water Cut-Offs MechanicalCombination Low Water Cut-Off/Pump Controllers for Steam Boilers

Ordering Information

Model Part WeightNumber Number Description lbs. (kg)

194 166600 Combination low water cut-off/ 72.0 (32.7)pump controller w/Series 5 switch

194-A 166700 194 w/alternate tappings 72.0 (32.7)194-A-7B 167100 194-A w/Series 7B switch 72.0 (32.7)

194-M 166900 194 w/manual reset 72.0 (32.7)

194-7B 167200 194 w/Series 7B switch 72.0 (32.7)194-7BM 167300 194-7B w/manual reset 72.0 (32.7)

194-B 166701 194 w/alternate tappings 72.0 (32.7

Dimensions, in. (mm)

Series 194Low Water Cut-Off/Pump Controllers

Electrical Ratings345 VA at 120 or 240 VAC

Y

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2

Electrical RatingsModels with 5 or 5-M Switch Models with 7B or 7B-M Switch

ApproximateDistance Above

Cast Line DifferentialSetting In. (mm) In. (mm)

Pump Off 23/16 (56) 11/16 (27)

Pump On 11/8 (29)

Burner On 13/8 (35) 13/8 (35)

Burner Off 0

Switch Settings

Values are 1/8 (3mm)

NOTE: Due to the slower operation of somemotorized valves, complete valve opening orclosing may occur at slightly differentlevels than indicated above.

Models with 5 or 5-M Switches

ApproximateDistance Above

Cast Line DifferentialSetting In. (mm) In. (mm)

Valve Full 23/16 (56) 11/16 (27)

ClosedValve Full 11/8 (29)

Open

Burner On 13/8 (35) 13/8 (35)

Burner Off 0

Models with 7B or 7B-M Switches

OPERATION Maximum Pressure:Series 93/193: 150 psi (10.5 kg/cm2)Series 94/194: 250 psi (17.6kg/cm2)

PUMPOFF

BURNEROFF BURNER

CUT-OFF LEVELAT CAST LINE

23/16"(56mm)

PUMP OFFPUMP ON

(27mm)11/16"

BURNERCUT-OFF LEVELAT CAST LINE

BURNER OFF

(35mm)

BURNER ON

13/8"BURNERCUT-OFF LEVELAT CAST LINE

BURNER OFF

(35mm)

BURNER ON

13/8"

MOTORIZEDVALVE

CLOSED

BURNER

OFF BURNERCUT-OFF LEVELAT CAST LINE

23/16"(56mm)

MOTORIZEDVALVE

CLOSED

MOTORIZEDVALVEOPEN

(27mm)11/16"

Pump and Burner Switch Contact Ratings

Voltage Pilot Duty Only

120 VAC 345 VA240 VAC

Switch Ratings

Burner Valve

120 VAC 345 VA 0 - 135 ohms @ 24 VAC240 VAC

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3

If the control will be the primary lowwater fuel cut-off, size the steam (top) andwater (bottom) equalizing pipe lengths sothat the horizontal cast line on the body is1 1/2 (38mm) below the boilers normalwater level, but not lower than the lowestsafe permissible water level, as deter-mined by the boiler manufacturer.

OR

If the control will be the secondary lowwater fuel cut-off, size the steam (top) andwater (bottom) equalizing pipe lengths sothat the horizontal cast line on the body isat or above the lowest safe permissiblewater level, as determined by the boilermanufacturer.

STEP 1 - Determine the Position of the Low Water Cut-Off/Pump Controller

INSTALLATION

TOOLS NEEDED:Two (2) pipe wrenches, one (1) flathead screwdriver, and pipe thread dope.

IMPORTANT: Follow the boiler manufacturer'sinstructions along with all applicable codes andordinances for piping, blow-down valve, watergauge glass, tri-cock and electrical requirements.

11/2"

STEAM EQUALIZING PIPE

VERTICAL EQUALIZING PIPE

BLOW DOWN VALVE

NORMAL BOILER WATER LINE

AS A PRIMARYLOW WATER CUT-OFF/PUMPCONTROLLER

BURNER CUT-OFF LEVELAT CAST LINE

LOWESTPERMISSIBLEWATER LEVEL

WATEREQUALIZING

PIPE

STEAM EQUALIZING PIPE

VERTICAL EQUALIZING PIPE

BLOW DOWN VALVE

AS A SECONDARYLOW WATER CUT-OFF/PUMPCONTROLLER

BURNER CUT-OFF LEVELAT CAST LINE

LOWESTPERMISSIBLEWATER LEVEL

BURNER OFF

WATEREQUALIZING

PIPE

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4

AB

C

a. Mount and pipe the control (A) on vertical equalizingpipes (B) at the required elevation as determined inStep 1.

Install a full-ported blow-down valve (C) directly

below the lower cross.

NOTE:1 (25mm) NPT tappings are provided on Series93/193 controls.

1 1/4 (32mm) NPT tappings are provided for Series94/194 controls and 193-B Model.

STEP 2 - Installing the Low Water Cut-Off/Pump ControllerFor Series 93/193 or 94/194 (except 94-A, 193-D and 193-G Models)

A

E

C

D

a. Mount and pipe the control (A) with a vertical upper(D) and horizontal lower (E) equalizing piping at therequired elevation as determined in Step 1.

Install a full-ported blow-down valve (C) on the lowerbody connection.

NOTE:1 1/4 (32mm) NPT tappings are provided for 94-AModel control.

1 (25mm) NPT tappings are provided for 193-GModel control.

For 94-A and 193-G Models

A

C

G

a. Mount and pipe the control (A) with a horizontalupper and lower (G) equalizing piping at therequired elevation as determined in Step 1.

Install a full-ported blow-down valve (C) on the lowerbody connection.

NOTE:1 (25mm) NPT tappings are provided for 193-DModel control.

For 193-D Models

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5

a. Using a pipe wrench, remove the float blocking plugs (I)and dowels (H) from the control as shown below.

b. Using a pipe wrench, screw the pipe plugs provided withcontrol into the open tappings.

STEP 3 - Removing Float Blocking Plugs and Dowels

I

H

I

H

Series 93 / 94Series 193 / 194

CAUTIONThe plug and rod must be reinstalled before control is shipped installed on theboiler, and removed after boiler is placed and installed.

Failure to follow this caution may damage the float and operating mechanism.

!

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6

STEP 4 - Installing a Water Gauge Glass and Tri-Cocks

Tri-Cock Gauge Glass Tapping Gauge Glass Tapping

Tapping Pipe Size Center Distance

Unit B C D E F H J K L

193 12 (15) 12 (15) 12 (15) 12 (15) 12 (15) 1234 (324)

193-A1

2 (15)1

2 (15)1

2 (15)1

2 (15)1

2 (15) 111

2 (292)193-B 34 (20) 34 (20) 34 (20) 34 (20) 34 (20) 1234 (324)

193-D 12 (15) 12 (15) 12 (15) 1112 (292)

193-G 12 (15) 12 (15) 12 (15) 1112 (292)

194 12 (15) 12 (15) 12 (15) 12 (15) 12 (15) 1158 (295)

194-A 12 (15) 12 (15) 12 (15) 12 (15) 12 (15) 1278 (327)

194-B 34 (20) 34 (20) 34 (20) 34 (20) 34 (20) 1278 (327)

CUT-OFF LEVEL

CUT-OFFLEVEL

3"

3"

B

D

FE

C

KL

JH

a. Determine pipe size of tri-cock andsight glass tappings for the controlbeing installed including center

distance of sight glass tappings.NOTE:These items are not provided withcontrol and must be purchasedseparately

b. Install tri-cocks and gauge glass following

manufacturers instructions.

NOTE: A separate water column for installation ofgauge glass and tri-cocks may be required for boilers

with a Series 93 or Series 94 control. Follow themanufacturers instructions to install the water column.

GAUGE GLASS

(TYPICAL)

TRI-COCK

(TYPICAL)

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7

STEP 5 - Electrical Wiring

To prevent electrical shock, turn off the electrical power before making electrical connections.

This low water cut-off must be installed in series with all other limit and operating controls installed on theboiler. After installation, check for proper operation of all of the limit and operating controls, before leavingthe site.

Failure to follow this warning could cause electrical shock, an explosion and/or a fire, which could result in

property damage, personal injury or death.

! WARNING

2 4

1 3

BLUE

BOILER FEED PUMP OFFBURNER ONALARM OFF

BOILER FEED PUMP ONBURNER ONALARM OFF

BOILER FEED PUMP ONBURNER OFFALARM ON

RED

3 1

4 2

2 4

1 3

BLUE RED

3 1

4 2

2 4

1 3

BLUE RED

3 1

4 2

Switch OperationFor Series 93/193 or 94/194 with 5 or 5-M Switch

Wiring Diagrams

NOTE: The following diagrams are provided for refer-ence only. If available, manufacturers wiring diagrams

should always be followed to connect the devicebeing operated.

Red switch terminals 1 and 2 are for burner circuit contacts, terminals 3 and 4 are for the low level alarmcircuit contacts.

Blue switch terminals 3 and 4 are for feeder/pump control contacts, terminals 1 and 2 are for high levelalarm circuit contacts.

BLUE

NO. 5SWITCH

TO BURNERTO PUMP

LINE

1

2

3

4

4

3

RED

LINE

ALARM

TRANS.

Pump Control, Low Water Cut-Off and Alarm

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8

LOW WATER CUT-OFF CIRCUIT

BLUE

NO. 5SWITCH

BURNERSTARTER

1

2

RED

LINE

Low Water Cut-Off Only

PUMP CONTROL CIRCUIT

BLUE

NO. 5SWITCH

PUMPSTARTER

4

3

RED

LINE

Pump Control Only

ALARM CIRCUIT

BLUE

NO. 5SWITCH

ALARM

TRANS.

NEUTRAL

3

4

RED

LINE

Low Water Alarm Only

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9

TO BURNER

LINE

13

4

4

3

2

1

COMMON

CLOSING CIRCUIT

OPENING CIRCUIT

NO. 7BSWITCH

BLUERED

Proportional Control, Low Water Cut-Off and Alarm

2 4

1 3

BLUE

BURNER ONALARM OFFVALVE CLOSED

BURNER ONALARM OFFVALVE OPEN

BURNER OFFALARM ONVALVE OPEN

RED

3 1

4

2 4

1 3

BLUERED

3 1

4

2 4

1 3

BLUERED

3 1

4

NOTE: The 7B switch is a 135 ohm potentiometer slidewire control for use with an electric valve operator withthe same rating.

For Series 93/193 or 94/194 with 7B or 7B-M

Red terminals 1 and 2 are the burner circuit contacts, terminals 3 and 4 are the low level alarm circuitcontacts.

Blue terminal 3 is the common contact, terminals 1 and 4 are the output contacts.

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10

A

SWITCHCOVER

a. Remove two screws (A) and lift off switchcover.

b. Connect BX armored cable or Thinwall electricalmetal tubing to the integral fitting hub. Connectwires to terminals following appropriate wiringdiagram from pages 8 and 9 for your application.

NOTE: Follow local codes and standards whenselecting the types of electrical fittings and conduitto connect to control.

A

SWITCHCOVER

c. Replace switch cover and fasten with twoscrews (A).

Wiring Connections

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11

STEP 6 - Testing

CAUTIONImmediately turn off all power if the burner turns on with no water in the gauge glass.Investigate further before continuing procedure.

CAUTIONIf pump does not turn off or valve close, turn off water supply to boiler. Investigatefurther before continuing procedure.

a. Turn on power to boiler and pump circuits.

With the boiler empty, the pump should turn on (5 or 5-M switch models) or the valve open(7B or 7B-M switch models). The burner should remain off and boiler should begin to fill with water.

b. For Automatic Reset ModelsWhen water level in the gauge glass is approximately 1 3/8 (35mm) above the horizontal cast line,

the burner should turn on.

For Manual Reset ModelsWhen water level in the gauge glass is approximately 1 3/8 (35mm) above the horizontal cast line,

press the manual reset button and the burner should turn on.

c. For 5 or 5-M Switch ModelsWhen water level in the gauge glass is approximately 2 3/16 (56mm) above the horizontal cast line,the pump should turn off.

For 7B or 7B-M Switch ModelsWhen water level in the gauge glass is approximately 2 3/16 (56mm) above the horizontal cast

line, the valve should be closed.

d. With the water in the boiler at its normal level and burner on, SLOWLY open the blow-down valveuntil it is fully open. As the water level in the gauge glass begins to drop, verify that the following

occurs.For 5 or 5-M Switch ModelsWhen water level drops to approximately 1 1/8 (29mm) above the horizontal cast line, the pump

should turn on.When water level drops to the horizontal cast line, the burner should turn off.

For 7B or 7B-M Switch ModelsAs the water level drops, the valve should begin to open.When the water level drops to approximately 1 1/8 (29mm) above the horizontal cast line, the valve

should be full open.When the water level drops to the horizontal cast line, the burner should turn off.

e. Close the blow-down valve after burner turns off and restore water level to normal operating level.

f. Repeat testing procedure several times to ensure proper operation of control.

g. After testing and verification of control operation, the boiler can be returned to service.

Dimensions shown are typical. The following testing procedure is only meant to serve as a verification of proper

operating sequence.

!

!

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McDonnell & Miller

8200 N. Austin Ave.

Morton Grove, IL 60053

tel: 847-966-3700

fax: 847-966-9052

www.mcdonnellmiller.com

McDonnell & Miller

2006 ITT Corporation

Printed in U.S.A. 9-06 246043

MAINTENANCESCHEDULE: Blow down daily when the boiler is in

operation. Control should be blown down dailyto flush accumulation of sediment from floatchamber and verify operation of switches.

Remove head assembly and inspect water-side components annually. Replace headassembly if any of the internal components areworn, corroded or damaged or if control nolonger operates properly.

Inspect the float chamber and equalizingpiping annually. Remove all sedimentand debris.

Replace head mechanism every 5 years.More frequent replacement may be requiredwhen severe conditions exist such as rapidswitch cycling, surging water levels, and useof water treatment chemicals.

Replace unit every 15 years.More frequent replacement may be requiredwhen severe conditions exist.

PROCEDURE:

1. Blow down the control when the water level isat its normal position and the burner is on.Slowly open the blow-down valve until it is fullyopen and observe the water level fall in thegauge glass. Close the valve after verifying that

the pump contacts have closed and the burnershuts off. If the pump does not turn on andburner turn off when water level is lower,immediately shut off power to the pump andboiler and correct the problem.

To prevent serious personal injury from steampipe blow down, connect a drain pipe to thecontrol opening to avoid exposure to steamdischarge.

Failure to follow this caution could causepersonal injury.

! CAUTION

TROUBLESHOOTINGErratic operation of the control is the most common symptomthat occurs. Erratic operation can be defined as pump and/orburner switches not switching at proper levels. Refer to the

following list of items to check if the control is not operatingproperly.

1. Float Ball is CrushedCrushed floats are typically caused by improper blow-down. Drain piping from blow-down valve to drain shouldbe checked for proper pitch and the blow-down procedurefollowed when blowing down the control. Purchase andinstall a new float ball after investigating and correctingthe problem.

2. Float Ball is Filled with WaterThe seam weld on the float can sometimes deteriorate.This can be caused by the type of chemical treatment

used in the boiler.While this is a rare occurrence, thechemical treatment supplier should be consulted to deter-mine if a reaction could occur. Purchase and install a newfloat ball after investigating and correcting the problem.

3. Float Arm Springs are BentThe pivot springs located on either side of the float rodshould be flat and straight. If they become bent, the usualcause is mishandling of the unit during installation orimproper blow-down. The control should never be pickedup by the float ball or allowed to hang from the bowl by thefloat. Drain piping from blow-down valve to drain should bechecked for proper pitch and the blow-down procedure

followed when blowing down control. Purchase and installnew control or head mechanism after investigating andcorrecting the problem.

4. Switch Contact Springs BrokenThe contact springs can break if the electrical rating isexceeded. Purchase and install new switch assembly orhead mechanism after investigating and correcting theproblem.

5. Switch Contact Springs MisalignedMisalignment of the contact arms is usually associatedwith damage to the control during shipment or installation.Purchase and install new switch assembly or head

mechanism after investigating and correcting the problem.

6. Internal (Wetted) Parts DirtyThe internal parts can operate improperly if dirt, scale orrust is allowed to build.This condition can be a result ofnot blowing down the control as recommended and/orimproper boiler water chemical treatment. Purchase andinstall new control or head mechanism after investigatingand correcting the problem.

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Pressure Limits and ControlsCommercial/Industrial Combustion Controls

Mercury-Free

Control Solutions

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Product Usage Service Operation Reset TypeP

L91A

Modulatingpressure control(motor or valve)

Steam, Air,Noncombustible gases,

Noncorrosive liquids

(1) Pressure proportioning, 135 ohm(Series 90 Mod Motor or V9055)

Not ApplicableL91B

L91D(2) Pressure proportioning, 135 ohm

(Series 90 Mod Motor or V9055)

L404FHigh-limit controlor On/off control

with Alarm contacts



(1) SPDT Break/Make on rise or(1) SPST Break on risea

Auto recycle

1

L404VLow-limit control

or On/off control Oil

(1) SPST Make on risea

L404THigh-limit controlor On/off control

(1) SPST Break on risea

L4079A

High-limitcontrol



(2) SPST Break on rise

Manual resetL4079B


L4079W Oil

P7810C

High-limit control +



(2) SPST Break on rise +(1) Alarm contacts +

Manual reset

On/off control + Auto recycle

Modulatingpressure control(motor or valve)

(1) Pressure proportioning, 4-20 mA Not Applicable

L408JHigh-limit controlor On/off control

with Alarm contacts

Vapor Heatingor Liquid, Air,

Noncombustiblegases, Ammonia,

Oxygen, Distilled water

(1) SPDT Break/Make on rise

Auto recycle0-

L408JLow-limit controlor On/off control

(1) SPST Make on risea

C6097A Gas pressureswitch;

Safety limit withAlarm contacts

Natural gas,LP gas, Nitrogen, Air

(1) SPDT Break/Make on fallManual reset or

Auto recycle

C6097B (1) SPDT Break/Make on rise

C437DIndustrial gas

pressure switch;Safety limit

Natural gas,LP gas, Nitrogen, Air


Manual reset

C437E (1) SPST Break on fall

Make The Mercury-Free Switch!Obtain reliable pressure control, modulation and safety with Honeywellsextensive line of mercury-free pressure controls and limits.

Notes:aSome L404F, L404V and L408J SPST make on rise models have terminal B omitted for ANSI/CSA miswiring compliancebSome L404F and L91 models have 1/4" - 19 BSPT mounting, ground screw and metric scale for the European market

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essureanges,psi

PressureRanges,

inches wcDifferential Approvals Pipe

AmbientTemperature

EnclosureType

Contact Ratings

0-15,5-150,10-300

Non-adjustable

NotApplicable

1/4" 18NPTb

32 to 150 F NEMA 124Vdc / 24VacControl Circuit

Adjustable throttle

-8, 2-15,5-50,

10-150,20-300 Adjustable

subtractivedifferential

CSA, UL1/4" 18

NPTbMaximum

150 FNEMA 1

120Vac: 8FLA, 48LRA240Vac: 5FLA, 30LRA

5-50,10-150

2-15,10-150

Not Applicable CSA, UL1/4" 18

NPTMaximum

150 FNEMA 1


2-15,5-50,

10-150,20-300

10-150

0-15,0-150,0-300

Non-adjustable

CSA, UL,FM,

CSD-1, FCC

1/2" 14NPT

32 to 140 F NEMA 1120Vac, 50/60 Hz9.8FLA, 58.8LRA

Adjustable subtractive

Adjustable throttle

16 oz/in2,0-4 psi

Adjustablesubtractivedifferential

CSA, UL1/4" 18

NPT-35 to 150 F NEMA 1


1.5-7

0.4-5, 3-21,

12-60 Fixed additiveor subtractive

differential

CSA, UL,FM,

CSD-1, IRI

Flange or1/4" 18 NPT

-40 to 140 F IP54120Vac: 3FLA, 18LRA240Vac: 3FLA, 18LRA

3-21, 12-60

0.5-5,1-10

1-26 Fixed subtractive

CSA, UL,FM

1/2" 14,1/8" 27 NPT

32 to 125 F NEMA 1120Vac: 8FLA, 48LRA240Vac: 5FLA, 30LRA

0.5-5.5, 1-26 Fixed additive

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63-9727May 2007 2007 Honeywell International Inc.

The Honeywell Solution

Get the Honeywell advantage by utilizing the full complement of

mercury-free controls for a complete and reliable pressure control solution.

a Product cross reference counter mat insert.

For available accessory information, please refer to the applicable

Product Data sheet listed above or contact your Honeywell distributor.

Further InformationProduct

DataSpecification

DataTechnicalBrochure

Sell Sheet

L91A, B, D Proportioning PressureTrolControls 60-2152 65-0059 63-9727

L404F, V, T PressureTrolControls 71-2429 63-9342a 63-9727

L4079A, B, W PressureTrolLimit Controls 60-2156 63-9727

P7810C PressureTrolControl 65-0285 63-9727

L408J VaporStatControls 65-0287 63-9727

C6097A, B Gas Pressure Switches 65-0237 63-9727 63-9340

C437D, E Industrial Gas Pressure Switches 68-0286 63-9727

Download from: http://customer.honeywell.com

Automation and Control Solutions

In the U.S.:

Honeywell

1985 Douglas Drive North

Golden Valley, MN 55422-3992

In Canada:

Honeywell Limited

35 Dynamic Drive

Toronto, Ontario M1V 4Z9

www.honeywell.com

To Learn More

For more information please contact your Honeywell

Distributor. Or visit http://customer.honeywell.com.

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VIKING PUMP, INC.A Unit of IDEX CorporationCedar Falls, IA 50613 USA

SECTION TSM 144

PAGE 1 OF 10

ISSUE C

TECHNICAL SERVICE MANUAL

CONTENTS

INTRODUCTIONThe illustrations used in this manual are for identification

purposes only and cannot be used for ordering parts. Obtain a

parts list from the factory or a Viking representative. Always

give complete name of part, part number and material with

model number and serial number of pump when ordering

repair parts. The unmounted pump or pump unit model

number and serial number are on the nameplate.

In the Viking model number system, basic size letters are

combined with series number (4195 and 495) are used to

indicate either an unmounted pump or mounted pump unit.

FIGURE 1

GG, HJ and HL4195 SERIES

Foot Type Unmounted Pump with Tapped Ports

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

Safety Information. . . . . . . . . . . . . . . . . . . . 2

Special Information . . . . . . . . . . . . . . . . . . . 3

Special Mechanical Seals . . . . . . . . . . . . . . . . 3

Maintenance . . . . . . . . . . . . . . . . . . . . . . 3

Disassembly . . . . . . . . . . . . . . . . . . . . . . 4

Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7

Thrust Bearing Adjustment . . . . . . . . . . . . . . . 8

Installation of Carbon Graphite Bushings. . . . . . . . 8

Pressure Relief Valve Instructions . . . . . . . . . . . 9

FIGURE 2

AS, AK and AL4195 SERIES

Foot Type Unmounted Pump with Tapped Ports

FIGURE 3

GG, HJ and HL495 SERIES

Unmounted Pump with Tapped Ports

UNMOUNTED PUMP UNITS

Foot Mounted

Units are designated by the

unmounted pump model

numbers followed by a letter(s)

indicating drive style.

D = Direct Drive

GG4195

HJ4195

HL4195

AS4195

AK4195

AL4195

Flange Mounted

M = Horizontal Direct Drive

GG495

HJ495

HL495

AS495

AK495

AL495

This manual deals only with Series 4195 and 495 Heavy

Duty Pumps. Refer to Figures 1 through 14 for general

configuration and nomenclature used in this manual. Pump

specifications and recommendations are listed in Catalog

Section 144, Series 4195 and 495 Heavy Duty Pumps.FIGURE 4

AS, AK and AL495 SERIES

Unmounted Pump with Tapped Ports

HEAVY-DUTY PUMPS

SERIES 4195 AND 495

SIZES GG - AL

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SECTION TSM 144 ISSUE C PAGE 2 OF 10

BEFORE opening any liquid chamber (pumping

chamber, reservoir, relief valve adjusting cap fitting,

etc.) be sure that :

Any pressure in the chamber has been completely

vented through the suction or discharge lines or

other appropriate openings or connections.

The pump drive system means (motor, turbine,

engine, etc.) has been locked out or otherwise

been made non-operational so that it cannot be

started while work is being done on the pump.

You know what material the pump has been

handling, have obtained a material safety data

sheet (MSDS) for the material, and understand

and follow all precautions appropriate for the safe

handling of the material.

BEFOREoperating the pump, be sure all drive guards

are in place.

DO NOT operate pump if the suction or discharge

piping is not connected.

DO NOTplace fingers into the pumping chamber or

its connection ports or into any part of the drive train

if there is any possibility of the pump shafts being

rotated.

DO NOTexceed the pumps rated pressure, speed, and

temperature, or change the system/duty parameters

from those the pump was originally supplied, without

confirming its suitability for the new service.

BEFOREoperating the pump, be sure that:

It is clean and free from debris

all valves in the suction and discharge pipelines

are fully opened.

All piping connected to the pump is fully supported

and correctly aligned with the pump.

Pump rotation is correct for the desired direction

of flow.

INSTALL pressure gauges/sensors next to the

pump suction and discharge connections to monitor

pressures.

USEextreme caution when lifting the pump. Suitable

lifting devices should be used when appropriate. Lifting

eyes installed on the pump must be used only to lift

the pump, notthe pump with drive and/or base plate.

If the pump is mounted on a base plate, the base plate

must be used for all lifting purposes. If slings are used

for lifting, they must be safely and securely attached.

For weight of the pump alone (which does not include

the drive and/or base plate) refer to the Viking Pump

product catalog.

DO NOTattempt to dismantle a pressure relief valve

that has not had the spring pressure relieved or is

mounted on a pump that is operating.

AVOID contact with hot areas of the pump and/or

drive. Certain operating conditions, temperature

control devices (jackets, heat-tracing, etc.), improper

installation, improper operation, and improper

maintenance can all cause high temperatures on the

pump and/or drive.

THE PUMP must be provided with pressure protection.

This may be provided through a relief valve mounted

directly on the pump, an in-line pressure relief valve,

a torque limiting device, or a rupture disk. If pump

rotation may be reversed during operation, pressure

protection must be provided on bothsides of pump.

Relief valve adjusting screw caps must always point

towards suction side of the pump. If pump rotation is

reversed, position of the relief valve must be changed.

Pressure relief valves cannot be used to control pump

flow or regulate discharge pressure. For additional

information, refer to Viking Pumps Technical Service

Manual TSM 000 and Engineering Service Bulletin

ESB-31.

THE PUMPmust be installed in a matter that allows

safe access for routine maintenance and for inspection

during operation to check for leakage and monitor

pump operation.

WARNING

SAFETY INFORMATION AND INSTRUCTIONS

Danger - Failure to follow the indicatedinstruction may result in serious injuryor death.

Warning - In addition to possible seriousinjury or death, failure to follow theindicated instruction may cause damageto pump and/or other equipment.

IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY

OR DEATH AND/OR RESULT IN DAMAGE TO PUMP AND/OR OTHER EQUIPMENT. VIKINGS WARRANTY

DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION, OPERATION OR MAINTENANCE.

THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION, OPERATION OR

MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP. PUMP MUST BE INSTALLED, OPERATED

AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS.

THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES.

WARNINGSymbol

Legend :

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WARNING

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WARNING

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WARNING

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WARNING

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WARNING

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SPECIAL INFORMATION

MAINTENANCE

PRESSURE RELIEF VALVES:

1. Viking pumps are positive displacement pumps and

must be provided with some sort of pressure protection.

This may be a relief valve mounted directly on the pump,

an inline pressure relief valve, a torque limiting device or

a rupture disk.

2. There are relief valve options available on those pump

models designed to accept a relief valve. Options may

include a return to tank relief valve. Pumps equipped

with a jacketed head plate are generally not available

with a relief valve.

3. If pump rotation is reversed during operation, pressure

protection must be provided on both sides of the pump.

4. The relief valve adjusting screw cap must always pointtowards the suction side of the pump. If pump rotation is

reversed, remove the pressure relief valve and turn end

for end. Refer to Figure 5.

5. Pressure relief valves should not be used to control flow

or regulate discharge pressure.

For additional information on pressure relief valves, refer

to Technical Service Manual TSM 000 and Engineering

Service Bulletin ESB-31.

Series 4195 and 495 pumps are designed for long, trouble-

free service life under a wide variety of application conditions

with a minimum of maintenance. The points listed below will

help provide long service life.

CLEANING PUMP: Keep the pump as clean as possible.

This will facilitate inspection, adjustment and repair work

and help prevent overlooking a dirt covered grease fitting.

STORAGE:If the pump is to be stored, or not used for six

months or more, the pump must be drained and a light coat

of non-detergent SAE 30 weight oil must be applied to all

internal pump parts. Lubricate the fittings and apply grease

to the pump shaft extension. Viking suggests rotating pumpshaft by hand one complete revolution every 30 days to

circulate the oil.

SUGGESTED REPAIR TOOLS: The following tools must

be available to properly repair Series 4195 and 495 pumps.

These tools are in addition to standard mechanics tools such

as open end wrenches, pliers, screw drivers, etc. Most of the

items can be obtained from an industrial supply house.

1. Soft Headed hammer

2. Allen wrenches (set screws & special mechanical seals)

3. Snap Ring Pliers

INTERNAL Viking Part No. 2-810-047-999

GG-HJ-HL 4195-495

EXTERNAL Viking Part No. 2-810-029-375GG-HJ-HL 4195-495

4. Mechanical Seal Installation Sleeve

2-751-001-730 for 0.75 inch seal; GG 4195-495

2-751-004-730 for 1.25 inch seal; AS-AL 4195-495

5. Bearing Locknut Spanner Wrench 2-810-043-375

6. Spanner Wrench, adjustable pin type for use on bearing

housing end cap. 2-810-008-375

7. Brass bar

8. Arbor press

SPECIAL MECHANICAL SEALS:

This bulletin illustrates the mechanical seal which is

standard in the catalog pump. A Seal Installation Drawing

will be furnished with a pump fitted with a non-standard

mechanical seal. Consult this Seal Installation Drawing

before disassembling pump.

Modifications are required to install Teflon mechanical seals

in these pumps. Contact the factory for specific information.

ROTATION:Viking pumps operate equally well in a clockwise

or counterclockwise rotation. Shaft rotation determines which

port is suction and which is discharge. Suction Port is where

pumping elements (gear teeth) come out of mesh.

FIGURE 5

RELIEF VALVE ADJUSTING SCREW CAP

SUCTION DISCHARGE

Teflon is a registered trademark of E.I. Dupont Co.

DANGER !

Before opening any Viking pump liquidchamber (pumping chamber, reservoir,relief valve adjusting cap fitting, etc.)Be sure:

1. That any pressure in the chamber hasbeen completely vented through thesuction or discharge lines or otherappropriate openings or connections.

2. That the driving means (motor, turbine,engine, etc.) has been locked outor made non-operational so that itcannot be started while work is beingdone on pump.

3. That you know what liquid the pumphas been handling and the precautionsnecessary to safely handle the liquid.

Obtain a material safety data sheet(MSDS) for the liquid to be sure theseprecautions are understood.

Failure to follow above listedprecautionary measures may result inserious injury or death.

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FIGURE 6

CUTAWAY FOR MODELS GG, HJ AND HL4195

CASING

DISASSEMBLY 1. Refer to Figures 7 & 8, page 5 for model to bedisassembled and name of parts. Models 4195 & 495

are disassembled and assembled in the same manner.

The difference between these models is the casings.

2. Mark the head and casing before disassembly to insure

proper reassembly.

3. NOTE: The four valve capscrews, valve and gasket

must be removed from the GG4195-495 model before

the six head capscrews are removed.

Remove the head capscrews.4. Tilt the top of the head back when removing to prevent

the idler from falling off the idler pin.

5. Remove the idler and bushing assembly. If the idler

bushing needs replacing, see Installation of Carbon

Graphite Bushings,page 8.

6. Insert a brass bar or piece of hardwood in the port

opening and between the rotor teeth to keep the shaft

from turning. Turn the locknut counterclockwise and

remove locknut. See Figure 9 or 10, page 6.

7. Loosen the two setscrews in the face of the bearing

housing and turn the thrust bearing assembly

counterclockwise and remove from casing. SeeFigure

9 or 10, page 6.

8. GG, HJ, HL: Remove the snap ring from the shaft.

See Figure 9, page 6.

AS, AK, AL: Remove the bearing spacer from the shaft.


9. Remove the brass bar or piece of hardwood from the

port opening.

ROTOR

IDLERHEAD

CASING

SHAFT

IDLER PIN

PRESSURE RELIEF VALVE

HEAD GASKET

MECHANICAL SEAL

BALL BEARINGS

SNAP RINGS

DANGER !







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FIGURE 7 - EXPLODED VIEW FOR MODELS GG, HJ AND HL 4195 AND 495

ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART

1 Locknut 8 Casing (4195) 14 Head O-Ring

2 Snap Ring (Outer) 8A Casing (495) 15 Idler Pin

3 Ball Bearing (Outer) 9 Pipe Plug 16 Head and Idler Pin Assembly

4 Snap Ring for Shaft * 10 Mechanical Seal 17 Capscrew for Head5 Bearing Housing 11 Rotor and Shaft Assembly 18 Gasket for Relief Valve

6 Snap Ring (Inner) 12 Idler Bushing 19 Relief Valve

7 Ball Bearing (Inner) 13 Idler and Bushing Assembly 20 Capscrew for Valve

ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART

1 Locknut 9 Bearing Retainer Washer 16 Mechanical Seal

2 Bearing Spacer Collar 10 Casing (4195) 17 Idler Bushing

3 End Cap for Bearing Housing 10A Casing (495) 18 Idler and Bushing Assembly

4 Lip Seal for Bearing Housing 11 O-Rings for Relief Valve 19 Head O-Ring

5 Ball Bearing (Outer) 12 Relief Valve 20 Idler Pin

6 Bearing Housing 13 Pipe Plug 21 Check Valve

7 Bearing Spacer 14 Capscrew for Valve 22 Head and Idler Pin Assembly

8 Ball Bearing (Inner) 15 Rotor and Shaft Assembly 23 Capscrew for Head

Modifications to the pump casing and rotor are required for installation

of optional Teflon mechanical seal. Consult the factory.

Modifications to the pump casing and rotor are required for installation

of optional Teflon mechanical seal. Consult the factory.

FIGURE 8 - EXPLODED VIEW FOR MODELS AS, AK AND AL 4195 AND 495

* Not used on GG size pumps.

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10. The rotor and shaft can now be removed by tapping on

the end of the shaft with a lead hammer or, if using a

regular hammer, use a piece of hardwood between the

shaft and hammer. The rotary member of the seal will

come out with the rotor and shaft.

11. AS, AK, AL:Remove the bearing retainer washer. The

washer may have stayed with the rotor and

shaft when removed or is against the ballbearing. SeeFigure 10.

12. Remove the mechanical seal rotary member and spring

from the rotor and shaft assembly.

13. GG, HJ, HL:Remove the inner snap ring and single row

ball bearing from the casing.

AS, AK, AL:Remove the single row ball bearing from

the casing.

14. Remove the seal seat or stationary part of the seal from

the casing.

15. Disassemble the thrust bearing assembly.

GG, HJ, HL:Remove the outer snap ring from the

bearing housing and remove the ball

bearing. SeeFigure 9.

AS, AK, AL: Loosen the two setscrews in the flange

outside diameter. Rotate the end cap and

lip seal counterclockwise and remove.

Remove the ball bearing. SeeFigure 10.

The casing should be examined for wear, particularly in the

area between the ports. All parts should be checked for wear

before the pump is put together.

When making major repairs, such as replacing a rotor and

shaft; it is advisable to also install a new mechanical seal,

head and idler pin, idler and bushing. See Installation of

Carbon Graphite Bushings, page 8.

SHAFT SNAP RING

OUTER BALL BEARING

BEARING HOUSING

INNER SNAP RING

INNER BALL BEARING

SETSCREW

SHAFT

OUTER SNAP RING

LOCKNUT

FIGURE 9 - THRUST BEARING ASSEMBLY GG, HJ AND HL SIZES

FIGURE 10 - THRUST BEARING ASSEMBLY AS, AK AND AL SIZES

BEARING RETAINER WASHER

BEARING SPACER

SETSCREW

LOCKNUT

LIP SEAL

END CAP

NYLON INSERT

SHAFT

INNER BALL BEARING

BEARING HOUSING

SETSCREW

BALL BEARING

BEARING SPACER COLLAR

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ASSEMBLYStandard Mechanical Seal

(Synthetic Rubber Bellows Type)

Clean all parts thoroughly and examine for wear or damage.

Check the lip seals, ball bearings, bushing and idler pin and

replace if necessary. Check all other parts for nicks, burrs,

excessive wear and replace if necessary.

Wash the bearings in clean solvent. Blow out the bearings

with compressed air. Do not allow the bearings to spin; turn

them slowly by hand. Spinning the bearings will damage

the race and balls. Make sure the bearings are clean, then

lubricate with non-detergent SAE 30 weight oil and check

for roughness. Roughness can be determined by turning

the outer race by hand. Replace the bearings if they haveroughness.

Be sure the shaft is free from nicks, burrs and foreign

particles that might damage the mechanical seal. Scratches

on the shaft in seal area will provide leakage paths under the

mechanical seal. Use a fine emery cloth to remove scratches

or sharp edges.

READ CAREFULLY BEFORE REASSEMBLING PUMP

The seal used in this pump is simple to install and good

performance will result if care is taken during installation.

The principle of a mechanical seal is contact between the

rotary and stationary members. These parts are lapped to

a high finish and their sealing effectiveness depends on

complete contact.

Prior to installing the rotary portion of the mechanical

seal, prepare and organize the rotor shaft, head and idler

assemblies and appropriate gaskets for quick assembly.

Once the rotary portion of the mechanical seal is installed

on the rotor shaft, it is necessary to assemble the parts as

quickly as possible to insure the seal does not stick to the

shaft in the wrong axial position. The seat will stick to the

shaft after several minutes setting time.

Never touch the sealing faces with anything except clean

hands or clean cloth. Minute particles can scratch the seal

faces and cause leakage.

1. Coat the idler pin with non-detergent SAE 30 weight oil

and place idler and bushing on idler pin in the head. If

replacing a carbon graphite bushing, refer to Installation

of Carbon Graphite Bushings,page 8.

2. Clean the rotor hub and casing seal housing bore. Make

sure both are free from dirt and grit. Coat the outer

diameter of seal seat and inner diameter of seal housing

bore with non-detergent SAE 30 weight oil.

3. Start the seal seat in the seal housing bore. If force is

necessary protect the seal face with a clean cardboarddisc and gently tap it in place with a piece of wood. Be

sure the seal seat is completely seated in the bore.

4. Place a tapered installation sleeve on the shaft, refer to

Figure 11.The sleeve is furnished with GG, AS, AK and

AL replacement mechanical seals. Coat the rotor shaft,

tapered installation sleeve and inner diameter of the

mechanical seal rotary member with a generous amount

of non-detergent SAE 30 weight oil. Petrolatum may be

used but grease is not recommended.

5. Place the seal spring on the shaft against the rotor hub.

Refer to Figure 12.

6. Slide the rotary member, lapped contact surface facing

away from the spring, over installation sleeve on shaft

until just contacting the spring. Do not compress the

spring. Remove the installation sleeve.

7. Coat the rotor shaft with non-detergent SAE 30 weight

oil. Install the rotor and shaft into the casing, slowly

pushing until the ends of the rotor teeth are just below

the face of the casing. Take care not to damage the seal

seat.

8. Leave the rotor in this position. Withdrawal of the rotor

and shaft may displace the carbon seal rotating face and

result in damage to the seal.

9. Place the O-ring or gasket on the head and install the

head and idler assembly on pump. The pump head

and casing were marked before disassembly to insure

proper reassembly. If not, be sure the idler pin, which

is offset in the pump head, is positioned up and equal

distance between port connections to allow for proper

flow of liquid through the pump.

10. Tighten the head capscrews evenly.

11. If the pump was equipped with a relief valve and was

removed during disassembly, install on the head withnew O-Rings or gaskets. The relief valve adjusting screw

cap must always point towards the suction port. Refer to

Figure 5,page 3. For relief valve repair or adjustments,

seePressure Relief Valve Instructions,Page 9.

12. In 2005, the use of single seal bearings were phased

out. Pumps now use Sealed for Life bearings that

have seals on both sides. The new bearings can be

installed either side first and do not need to be packed

with grease. For older models with single seal bearings,

pack the inner ball bearing with multi-purpose grease,

NLGI #2.

FIGURE 11

SPRING MECHANICAL SEAL

(ROTARY MEMBER)

TAPERED SLEEVE

COAT WITH LIGHT OIL BEFORE ASSEMBLY

MECHANICAL SEAL

(ROTARY MEMBER)

SPRING

ROTOR HUB

SHAFT

FIGURE 12

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GG, HJ, HL: Drive the bearing into the bore. Tap the

inner race with a brass bar and lead

hammer to position bearing. Install the

inner snap ring.

AS, AK, AL: Install the bearing retainer washer over

the shaft before installing the ball bearing.

Install the ball bearing in the casing with

sealed side towards head end of the

pump. Drive the bearing into the bore. Tap

the inner race with a brass bar and lead

hammer to position the bearing.13. GG, HJ, HL:Install the shaft snap ring in groove in the

shaft. See Figure 9, page 6.

AS, AK, AL: Install the bearing spacer over the shaft

and against the single row ball bearing.


14. Pack the lubrication chamber between the inner ball

bearing and double row ball bearing in the thrust bearing

assembly approximately one-half full of multi-purpose

grease, NLGI #2. The thrust bearing assembly will take

the remaining space. See Figure 9 and 10, page 6.

15. Pack the double row ball bearing with multi-purpose

grease, NLGI #2.

GG, HJ, HL: Install the ball bearing into the bearing

housing with shield side toward the

coupling end of the shaft. See Figure 9,

page 6. Install the snap ring into bearing

housing to retain ball bearing. This snap

ring has a tapered edge to fit tapered

groove in bearing housing. The tapered

edge is located away from the ball bearing.

AS, AK, AL: Install the ball bearing into the bearing

housing. Install the lip seal in the bearing

housing end cap. The lip should face

towards the end of the shaft. Put the bearing

spacer collar in the lip seal and install in

the bearing housing and tighten the setscrews securely. SeeFigure 10, page 6.

16. Insert a brass bar or piece of hardwood through the port

opening between the rotor teeth to keep the shaft from

turning.

17. Start the thrust bearing assembly into casing. Turn by

hand until tight. This forces the rotor against the head.

Replace and tighten the locknut or shaft.

18. Remove the brass bar or hardwood from port opening.

19. Adjust pump end clearance, refer to Thrust Bearing

Adjustment.

Loosen the two screws in the face of the thrust bearing

assembly.

If the shaft cannot be rotated freely, turn the thrust bearing

assembly counterclockwise until the shaft can be turned

easily.

To set end clearance:

1. While turning the rotor shaft, rotate the thrust bearingassembly clockwise until a noticeable drag occurs. This

is zero end clearance.

2. Mark the position of the bearing housing with respect to

the casing.

3. Rotate the thrust bearing assembly counterclockwise the

distance listed below as measured on outside of bearing

housing.

4. After the adjustment is made, tighten the two setscrews

in the face of the bearing housing assembly to secure

the position.

For viscosities above 2500 SSU, add additional end

clearance (0.004 for GG, HJ and HL size pumps and

0.005 for AS, AK and AL size pumps).

When installing the carbon graphite bushings, extreme care

must be taken to prevent breaking. Carbon graphite is a brittle

material and is easily cracked. If cracked, the bushing will

quickly disintegrate. Using a lubricant and adding a chamfer

on the bushing and the mating part will help in installation.

The additional precautions listed below must be followed for

proper installation:

1. A press must be used for installation.

2. Be certain the bushing is started straight.

3. Do not stop pressing the operation until the bushing is in

the proper position, as starting and stopping may result

in a cracked bushing.

4. Check the bushing for cracks after installation.

DANGER !

Before starting pump, be sure all driveequipment guards are in place.

Failure to properly mount guards mayresult in serious injury or death.

THRUST BEARING ADJUSTMENTSeeFigures 9 and 10.

PUMP

SIZE

DISTANCE IN INCHES

ON O.D. OF BEARING

HOUSING

STANDARD

END

CLEARANCE

GG 0.44 (7/16) .003

HJ , HL 0.56 (9/16) .003

AS , AK , AL 0.5 (1/2) .003

INSTALLATION OF CARBON

GRAPHITE BUSHINGS

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Mark the valve and head before disassembly to ensure

proper reassembly.

1. Remove the valve cap.2. Measure and record the length of extension of the

adjusting screw. Refer to Aon Figures 13 and 14.

3. Loosen the locknut and back out the adjusting screw

until spring pressure is released.

4. Remove the bonnet, spring guide, spring and poppet

from the valve body. Clean and inspect all parts for wear

or damage and replace as necessary.

Reverse the procedures outlined under Disassembly. If

the valve is removed for repairs, be sure to replace in thesame position. The relief valve adjusting screw cap must

always point towards suction side of the pump. If the pump

rotation is reversed, remove the relief valve and turn end for

end. Refer to Figure 5, page 3.

PRESSURE RELIEF VALVE

INSTRUCTIONS

FIGURE 13

VALVE - GG, HJ and HL SIZES

FIGURE 14

VALVE - AS, AK and AL SIZES

VALVE - LIST OF PARTS

1. Valve Cap 6. Valve Body

2. Adjusting Screw 7. Valve Spring

3. Lock Nut 8. Poppet

4. Spring Guide 9. Cap Gasket

5. Bonnet

VALVE - LIST OF PARTS

1. Valve Cap 6. Valve Body

2. Adjusting Screw 7. Valve Spring

3. Lock Nut 8. Poppet

4. Spring Guide 9. Cap Gasket

5. Bonnet 10. Bonnet O-Ring

ASSEMBLY

DISASSEMBLY

DANGER !







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VIKING PUMP, INC.A Unit of IDEX CorporationCedar Falls, IA 50613 USA 2006 Viking Pump Inc.

All rights reserved

TECHNICAL SERVICE MANUALSECTION TSM 144

PAGE 10 OF 10

ISSUE C

WARRANTY

Viking warrants all products manufactured by it tobe free from defects in workmanship or material for aperiod of one (1) year from date of startup, providedthat in no event shall this warranty extend more thaneighteen (18) months from the date of shipment fromViking. If, during said warranty period, any productssold by Viking prove to be defective in workmanshipor material under normal use and service, and if suchproducts are returned to Vikings factory at Cedar Falls,Iowa, transportation charges prepaid, and if the productsare found by Viking to be defective in workmanshipor material, they will be replaced or repaired free ofcharge, FOB. Cedar Falls, Iowa.

Viking assumes no liability for consequentialdamages of any kind and the purchaser by acceptanceof delivery assumes all liability for the consequences ofthe use or misuse of Viking products by the purchaser,his employees or others. Viking will assume no fieldexpense for service or parts unless authorized by it inadvance.

Equipment and accessories purchased by Vikingfrom outside sources which are incorporated into anyViking product are warranted only to the extent of andby the original manufacturers warranty or guarantee,

if any.

THIS IS VIKINGS SOLE WARRANTY AND IS IN

LIEU OF ALL OTHER WARRANTIES, EXPRESSED

OR IMPLIED, WHICH ARE HEREBY EXCLUDED,

INCLUDING IN PARTICULAR ALL WARRANTIES

OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE. No officer or employee of

IDEX Corporation or Viking Pump, Inc. is authorized to

alter this warranty.

If a new spring is installed or if the pressure setting of the

pressure relief valve is to be changed from that which thefactory has set, the following instructions must be carefully

followed.

1. Carefully remove the valve cap which covers the

adjusting screw.

Loosen the locknut which locks the adjusting screw so

the pressure setting will not change during operation of

the pump.

2. Install a pressure gauge in the discharge line for actual

adjustment operation.

3. Turn the adjusting screw in to increase the pressure and

out to decrease the pressure.

4. With discharge line closed at a point beyond pressure

gauge, the gauge will show the maximum pressure the

valve will allow while the pump is in operation.

When ordering parts for the pressure relief valve, always

give the model number and serial number of the pump

as it appears on the nameplate and the name of the part

wanted. When ordering springs, be sure to give the pressure

setting desired.

PRESSURE ADJUSTMENT

IMPORTANT

DANGER !

Before starting pump, be sure all driveequipment guards are in place.

Failure to properly mount guards mayresult in serious injury or death.

HEAVY-DUTY PUMPS

SERIES 4195 AND 495

SIZES GG - AL

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B-700 Service Manual 11.27.07

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Transcript of B-700 Service Manual 11.27.07