Drum SSC150 Installation and operating manual

SERSER
SERSER
SERVICEVICE
VICEVICE
VICE
andand
andand
and
REPREP
REPREP
REPAIRAIR
AIRAIR
AIR
MANUMANU
MANUMANU
MANUALAL
ALAL
AL
TABLE OF CONTENTS PAGE
Safety 3
Dismantling pump head 6
Replacing front oil seals 7
Fitting rotorcase & shims 8
Rotor ass'y 9
Rotor nuts 10
Replacing rear oil seals 11
Timing gear (general & removal) 12
Removal of shaft ass'y 13
Bearings (general & removal) 13
Bearing ass'y 14
Shafts 15
Timing gear ass'y 16
Mechanical seals 18
Relief valve 20
Torque settings, wrench sizes 21
Parts list 22
SSC150
STAINLESS STEEL
CHEMICAL GRADE PUMP
SAFETYSAFETY
SAFETYSAFETY
SAFETY
PRECAPRECA
PRECAPRECA
PRECAUTIONSUTIONS
UTIONSUTIONS
UTIONS
INSIDE.INSIDE.
INSIDE.INSIDE.
INSIDE.
PLEASE SEEPLEASE SEE
PLEASE SEEPLEASE SEE
PLEASE SEE
PP
PP
PAA
AA
AGE 2GE 2
GE 2GE 2
GE 2

Page 2
This manual contains repair instructions for
complete dismantling and assembly of the Drum SSC150 pump.
For information regarding:
Pump Specifications
Installation
Operation
Routine Maintenance
Fault Finding
See:
INSTALLATION, OPERATION and MAINTENANCE MANUAL
which will have been supplied with the pump.

SAFETYSAFETY
SAFETYSAFETY
SAFETY
PRECAPRECA
PRECAPRECA
PRECAUTIONSUTIONS
UTIONSUTIONS
UTIONS
!Rotating shafts can be dangerous. You can snag clothes, skin, hair, hands, etc. This
can cause serious injury or death.
!Do not work under the vehicle when the engine is running.
!Do not work on a shaft (with or without a guard) when the engine is running.
!Do not engage or disengage driven equipment by hand from under the vehicle when the
engine is running.
!In order to avoid becoming entangled, install the power take-off and/or shaft behind the
frame rail, tanks, battery box, etc.
!If power take-off and/or shaft are still exposed after installation, install a guard.
!Install a support strap when servicing a driveshaft to prevent personal injury.
!A serious or fatal injury can occur . . .
if you lack proper training
if you fail to follow proper procedures
if you do not use proper tools and safety equipment
if you assemble driveline components improperly
if you use incompatible driveline components
if you use worn-out or damaged driveline components
if you use driveline components in a non-approved application.
!This manual contains safety instructions. Read, understand and follow this manual.
Get proper training
Learn and follow safe operating procedures
Use proper tools and safety equipment
Use proper components in good condition
Page 3

Potential Safety Hazards
Introduction
The following section gives information on handling, storage and disposal of parts and materi-
als used in the pumps which may be considered hazardous to your health.
Please pass this information on to your Safety Officer; he may need it to comply with Health
and Safety regulations.
The information contained here is brief. Full details are available and can be obtained from
your supplier.
General First Aid
If potentially hazardous substances are accidentally inhaled, or skin or eyes contaminated,
then the following basic precautions should be taken:
Inhalation - Remove to fresh air
Skin - Wash with soap and water
Eyes - Flush with water, seek medical attention
In all cases, if symptoms persist, seek medical attention.
Safety
The following safety measures MUST be carried out to prevent pump damage or injury:
1. Before installation, ensure the pump and any drive equipment conforms to all
applicable Safety Legislation.
2. Where hazardous or poisonous products have been pumped, the system should be
thoroughly neutralised and cleaned out.
3. Before proceeding to work on the pump, isolate the drive and pump from all power
and control sources.
4. Always use shut off valves to isolate the pump.
5. Make sure the pump head is depressurized before maintenance.
Page 4

Material Use Major Hazard
Silicone sealant. Gearbox seal retainers Release vapor at room
rearcover, general sealant. temperature.
Sealant. Gearbox seal retainers, rear Release vapor at room
(Red Hermetite) cover, general sealant. temperature. Highly
flammable, treat as fire
hazard.
Anti-Seize Bearings. Applied from aerosol.
Compounds. Release vapor. Dispose of
container as if pressurized.
Adhesives. Bearing nuts, relief valve Release vapor at room
(eg Permabond) adjustment rings. temperature.
Oil and Grease Oil - general lubrication Skin and eye irritant.
Grease - product seals,
timing gears, general
lubrication.
Plastic Compounds PTFE - o-rings, lip seals Releases fumes when heated.
(PTFE, gland packing.
Polypropylene, Polypropylene - gland
PVC) guards.
PVC - gland guards.
Elastomeric O-rings, lip seals. Releases fumes when heated.
Compounds
(eg Viton, Nitrile,
Neoprene, Polyurethane
Kalrez, Chemraz.
Paint External pump surfaces Releases dust and fumes if
machined. Treat waste as
fire hazard.
Page 5

Dismantling the Pump Head
Rotors
1. Ensure isolating valve to the pump are closed.
2. Unscrew the front cover dome nuts. Carefully remove the cover as some residual
pressure may still exist in the system.
Front cover
3. If the cover is stuck, simply loosen using a soft mallet aimed at the sides, where the
cover overlaps the rotor case profile. DO NOT LEVER OFF!
4. To aid further maintenance, it is advisable that the pump head is flushed out.
5. The pump is fitted with handed nuts. The top shaft has a left hand threaded nut,
and should be turned clockwise to remove it. The bottom shaft has a standard right
hand threaded nut. With the front cover removed, insert a wooden wedge to
prevent rotor rotation, while slackening off the rotor nuts for removal.
6. Before removing rotors, mark their positions relative to the shaft. Both rotors should
now be extracted by gently sliding them off their shaft splines.
7. Stubborn rotors may be released by removing the rotorcase nuts and lightly tapping
the rotorcase forward. DO NOT PRISE the rotors from behind.
NOTE: For routine maintenance it may not be necessary to remove the rotorcase. If
so, the rotors, rotorcase and o-rings mays now be inspected for wear and
damage. Refer to ROTOR ASSEMBLY for assembly of the pump.
Rotorcase
1. Disconnect pipe connections from the rotorcase.
2. Undo rotorcase nuts and remove rotorcase squarely from the locating dowels. Care
must be taken in supporting the rotorcase upon its removal, so as not to damage the
seals.
3. Special shaped shims will be found between the rotorcase and the gearcase.
These are used to determine the rotor clearances for a particular duty. Ensure shims
are marked for replacement in the same order on re-assembly.
4. It is now possible to remove the seals. One half of the seal will be in the rotorcase
and the other half on the shaft. These should be carefully removed and inspected
for wear or damage.
Page 6

Replacing Front Oil Seals
1. Follow the procedure for dismantling the pump head and removing the product seal.
2. There is now free access to the front bearing retainers which are held in place by
three socket head cap screws on each one. These should now be removed.
3. A lever may have to be used to separate the retainer from the gearcase face, as a
silicon sealant bonds the retainer to the gearcase.
4. The oil seals can be simply pressed out from the retainer and replaced using a
suitable tool. A fine grade abrasive cloth should be used to clean the internal faces
of the retainer before refitting new oil seals.
5. Thoroughly clean off the old sealant from the retainer and front face of the
gearcase. A new application of silicon sealant can now be applied.
6. Replace and tighten the six screws evenly to the recommended torque values. See
page no. 21.
7. Reassemble the pump head and product seals to the detailed procedures.
Fig. 1
Front
Seals
Front Seal
Carriers
Page 7

Fitting the Rotorcase and Shims
Correct shimming is critical to avoid damaging the pump.
Take care not to damage the product seals
when sliding rotorcase over the shafts.
First ensure that the product seals are correctly fitted. If old shims are being reused, ensure
that they are replaced in their original positions. The following procedure should be adopted if
new shims are to be fitted:
1. Fit thinnest shim over rotorcase studs both top and bottom. Fit o-rings over studs.
2. Locate the four rotorcase studs into the matching gearcase holes, ensuring that
gearcase dowels locate in holes in rotorcase. The gearcase nuts should be tight
ened to th required torque, see page 21.
3. Refit the rotors as detailed in ROTOR ASSEMBLY section.
4. By measuring the back clearances with feeler gauges, any additional shimming
required may be predetermined, to bring the clearance within tolerance.
5. Additional shims should be fitted, by repeating steps 1 and 2, and clearances
rechecked. It is essential that clearances come within tolerance, so the above
should be repeated until this is achieved. Clearances should be similar for both top
and bottom of the rotorcase.
6. Refit rotorcase and tighten gearcase nuts to the required torque, see page 21.
Radial
Clearance
0.018"
0.012"
2.851"
2.854"
Rotorcase Depth
4.263"
4.267"
Rotorcase Dia.
Back
Clearance
0.008"
0.006" mesh
0.008"
(min. at any mesh position)
Front
Clearance
0.013"
0.009"
Rotor
Length
2.833"
2.835"
Rotor Diameter
4.234"
4.236"
Page 8

Rotor Assembly
1. Before the rotors can be refitted onto their respective shafts, the sealing o-rings must be
inspected for damage and replaced as necessary.
2. To assist assembly, each rotor has a small dimple machined into it to identify the center
line of the master lobe. These must be visible from the front of the pump,
indicating that the rotors have been fitted the correct way round.
3. If rotor positions were marked prior to removal, then the rotors should be refitted one at
a time, being careful to line up the marks.
4. If no marks were made, and the pump is not fitted with hydraulic drive, then:
- Rotate the pump so that the keyway in the drive shaft is pointing vertically upwards.
- Fit rotors one at a time so that each dimple is pointing upwards on the vertical centerline.
5. If no marks were made and the pump is fitted with hydraulic drive,
then:
- Fit the first rotor on the shaft in any position.
- Rotate the pump so that the dimple on the first rotor is pointing
vertical upwards on the vertical centerline.
- Fit the second rotor on the bottom shaft, ensuring that the
dimple is also pointing upwards on the vertical centerline.
6. Rotate the shaft by hand to ensure there is no
metal to metal contact between the rotors.
7. The rotor nuts can now be tightened onto the shafts to the
recommended torque values.
8. Examine the front cover o-ring and replace as
necassary. Locate front cover and tighten the front
cover nuts to the recommended torque values.
Fig. 2 - Rotors
Page 9

Rotor Nuts
Both rotors on the pump are retained on the shaft by flanged rotor nuts. Each nut carries an
o-ring which seals the end of the rotor and shaft.
The rotor nuts are handed as follows:
Top Shaft - Left hand thread
Bottom Shaft - Right hand thread
Once the rotor nuts are removed, the o-rings must be carefully inspected for damage and
replaced if necessary.
On reassembly, the rotor nuts should be tightened to the correct torque settings.
Front Cover
Rotor Nut
Rotor
Shaft
Fig. 3
Page 10

Replacing Rear Oil Seals (Round shaft pumps only)
Read Safety Section before proceeding.
Pumps fitted with hydraulic drive do not have rear oil seals.
1. Access to the rear cover will be gained by removing guards, drive coupling or
pulleys.
2. Remove the oil plug and thoroughly drain the pump of oil. This may be reused if
collected in a clean tray.
3. Standard drive pumps have a deflector fitted to the drive shaft to restrict ingress of
fluids into the gearbox. Remove the deflector by loosening the socket head grub
screw which retains it to the shaft.
4. The rear cover is held in place by six screws, and a liquid gasket seals the cover to
the gearcase.
5. After removing all the screws, a sharp tap with a mallet and punch will break the
gasket seal.
6. The old oil seal can now be pressed out from the cover and replaced with a new
one.
7. A suitable liquid gasket should be applied to the rear cover and gearcase faces,
once both have been cleaned free from the old gasket.
8. Relocate the rear cover onto the gearcase and tighten screws to the required torque
settings.
9. Refit deflector over shaft, ensuring a small gap of approximately between the
deflector and the rear cover. Tighten socket head grub screw.
10. Remember to refill the pump with oil as required. Check oil level through the sight
glass.
Page 11

Timing Gear - General
The rear of each pump houses a pair of timing gears which synchronise the rotors to ensure
that they do not come into contact with each other.
The gears have internal splines which mate onto the respective shaft splines. Each gear is
retained on the shaft by a circlip which locates into a groove in the shaft.
Timing Gear - Removal
To aid removal, each gear is provided with threaded holes for fitting extractor tools. The
following procedure is recommended to remove the timing gears:
1. See Replacing Rear Oil Seals section for details of removing gearcase cover.
2. If pump is fitted with hydraulic drive, the drive adaptor must be removed from the
gear first. This can be done by removing the four socket head screws which retain
the adaptor to the gear.
3. Use a pair of circlip pliers to remove circlips.
4. Before removing gears, note the position of the timing marks. The timing marks will
be used on assembly. See Fig 9b and 9c, page 17.
5. Progressively ease each gear from its shaft, using a puller if necessary.
Timing Gear Circlip
Spline
Extraction Holes
Fig. 4
Page 12

Removal of Shaft Assemblies
1. Follow the procedures for removing pump head and front bearing retainers.
2. Remove product seal.
3. Remove gearcase rear cover and timing gears.
4. By gently tapping each shaft with a soft mallet, the shaft assemblies can be drawn
through the front end of the gearbox.
Bearings - General
The pump utilises taper roller bearings. These are arranged as a single front bearing and a
single rear bearing separated by a long spacer.
Fig. 5
Bearings - Removal
Removing the bearings is achieved by using a "C" spanner to release the notched bearing nut.
Each bearing has been heated then contracted onto the shaft, so a suitable pressing tool
MUST be used to remove them.
Page 13

Bearing Assembly
1. For easier assembly it is advisable that the shaft should first be mounted vertically
into a vise, with the rotor spline in the downwards position. A suitable anti-seize
compound should be applied to the bearing diameters.
2. The front bearing inner assembly should be heated to 120 degress C using either
an induction heater or an oil bath. Ensure that all necessary safety precautions are
taken while heating bearings.
3. The bearing should be carefully placed over the shaft with the largest diameter of
the taper downwards. Ensure that a positive fit is achieved on the front bearing
diameter against the shaft shoulder.
4. Fit outer bearing to front assembly.
5. Place the long bearing spacer over the shaft so that it locates against the outer
bearing face of the bearing just fitted.
6. The rear bearing should be heated as in 2. With the largest diameter of the inner
cones taper upwards, the bearing can be fitted.
7. Allow bearings to cool before proceeding.
8. Locate shaft horizontally in vice.
9. The shaft locking nut thread should now be coated with permabond grade 145
sealant or equivalent. Screw lock nut onto the shaft. Correct fitting is achieved
when the bearing lock nut is tightened up, while both bearings and spacer are
continously rotated, until the spacer can no longer be moved by finger pressure
alone.
Fig. 6
Page 14

Shafts - General
Each pump has two shafts which are housed within the gearcase. Both shafts have been
manufactured with two splines for rotor and timing gear location, In the standard pump the
'drive shaft' is easily identified as it is the longest of the two shafts, and has a keyway ma-
chined into it. This is the bottom shaft. For pumps fitted with hydraulic drive, the drive shaft
has an adaptor fitted to the timing gear, and is the top shaft. The remaining shaft is referred
to as the 'auxiliary shaft'.
Shafts - Refitting Assemblies
1. Locate the shaft alignment spacer into the bottom rear bearing bore of the gearcase.
Fig. 7.
2. Fit the drive shaft into the appropriate gearcase bore, which is on the same center
line as the coupled drive unit being used (standard drive - bottom, hydraulic drive -
top).
3. Fit the auxiliary shaft into the remaining bore of the gearcase.
4. The front bearing retainers can be located in position and tightened to the torque
required. Note: DO NOT USE silicon sealant at this stage.
5. Fit both rotors as detailed in Rotor Assembly section.
6. The difference in axial displacement should be measured using a depth micrometer.
By comparing the differences between each rotor, the axial displacement is
recorded, see Fig. 8.
7. If the axial displacement is above 0.012mm (0.0005"), the appropriate shaft should
be removed to gain access to the shaft alignment spacer. The spacer should be
ground down to give the correct axial displacement.
8. Once the correct displacement is achieved, the silicon sealant should be applied to
the seal retainers, and screws retightened to specific torque requirements.
Shaft
Alignment
Spacer
Fig. 7
Rotors
Shafts
Axial Displacement
Fig. 8
Page 15

Timing Gear Assembly
Incorrect fitting of timing gears will damage the pump.
Please read this section carefully.
The pump is supplied with the rotors set up so that no metal to metal contact occurs between
the rotors. When this was achieved each gear and shaft was marked with a dot punch, see
Fig 9b and 9c. The procedure for timing gear assembly is as follows:
1. Refer to the Rotor Assembly section for rotor and shaft keyway position.
2. Each shaft and gear spline is paired together by dot punch identity marks,
for example, two dots for both drive shaft and matching gear, and one dot each for
the auxiliary shaft remaining gear, see Fig. 9b.
3. Fit the drive shaft gear onto the drive shaft making sure the identity marks lie on the
same plane. Fit circlip.
4. Locate the remaining gear onto the auxiliary shaft, carefully engaging the teeth with
the drive shaft gear. The dot mark on the auxiliary gear tooth must be positioned
between the two dot marks on the drive shaft gear, see Fig. 9c. If new gears are
being fitted:
4.1 Load one gear onto the drive shaft spline. Fit circlip.
4.2 Locate the remaining gear onto the auxiliary shaft spline and engage the teeth into
the drive shaft gear.
4.3 Check the clearances of the rotors with feeler gauges at the measurement positions
shown in Fig. 9a. If the clearances are approximately equal either side, turn the
drive shaft to ensure there is no interference between the rotors.
4.4 If clearances are correct, proceed to step 5.
4.5 If the clearances are incorrect, the auxiliary gear will have to be removed, rotated by
3 teeth, and replaced.
4.6 To move the gears, mark (with a suitable pen) the tooth of the auxiliary shaft gear
which fully engages with the drive shaft gear teeth.
4.7 Repeat the above until the correct clearances are obtained. The gears and shafts
should be dot punched as detailed in procedure step 2, to avoid repetition of the
above in future maintenance of the pump.
5. Now that the rotors have been correctly timed, the remaining circlip should be care
fully relocated in the shaft recess using circlip pliers. If the pump is fitted with
hydraulic drive, the drive adaptor should now be replaced.
Page 16

Timing Gear Assembly
Mesh
Mesh
Auxiliary Shaft Gear
Drive Shaft Gear
Fig. 9c
Fig. 9b
Fig. 9a
Page 17

Mechanical Seal - Assembly
Seal faces and seals are manufactured from brittle materials.
Care must be taken fitting when not to chip these components.
1. Lightly lubricate the 'O' ring (A) with a suitable food quality grease and locate in the
recess in the rotorcase bore.
2. Lightly grease the 'L' ring (F) and insert into the rotary seal ring (C).
3. A pin is located in the rotary seal ring (C). Carefully slide the ring over the shaft so
that the pin locates in the slot machined into the shaft.
4. Place the wave spring (D) over the static ring (E).
5. Push the static ring (E) with wave spring (D) into the flat sided bore of the rotorcase
and through the 'O' ring (A).
7. Offer the rotorcase onto the locating dowels of the gearcase, taking care not to
damage the seal against the shaft.
8. Follow the procedures for fitting the rotorcase and rotors.
Page 18
Mechanical Seal - General
Mechanical seals are precision made to provide good sealing qualities. Careful attention to
the following will prevent seal leakage:
1. Take care with seal faces when removing or refitting the
seal.
2. DO NOT place seals face down on bench. Seal faces
may easily be damaged.
3. 'O'rings and 'L' shaped elastomers should be protected
and regularly inspected.
The seal consists of a rotary seal ring (C), which is driven
by the shaft by means of a pin locating in a slot on the
shaft. An 'L' shaped elastomer ring (F) seals the rotary
ring to the shaft.
A static seal ring (E), the mating seal face, sit in the flat
sided bore of the rotorcase to prevent it rotating.
Behind the static seal ring, a wave spring (D) applies a
force to maintain contact between both static and rotary
seal faces. A clip (B), held in place by a set screw, in the
rotorscase restricts axial movement of the static seal
durring assembly.
An 'O'ring (A) sits in a groove within the rotorcase bore
providing a seal onto the static seal ring.
Item Description
A 'O' ring
B Retaining Clip
C Rotary Seal Ring
D Wave Spring
E Static Seal Ring
F 'L' ring
B
C
A
DFE

Page 19
Double Lip Seal - General
Note: Before use, chemical compatibility must be
verified for the following compounds present or
recommended.
A. 'O'rings - Viton
B. 'O'ring lubricant: Dow Silicon III.
C. Lip seal lubricant: Molykote FS-3451 (Dow Corning)
• Careful attention to the following will prevent seal
leakage:
• Take care with lip seal surfaces when removing or
refitting the seal.
• 'O'rings and Lip seals should be protected from shaft
splines when assembling and disassembling the pump.
• The seal consists of a rotary seal sleeve (6), which is
retained on the shaft by means of a pin locating in a slot on
the shaft. An 'O' ring (9) seals the rotary sleeve to the
shaft.
• Housing plate (5), and 'O'ring (8) mounts to the pump
rotor case and houses the lip seal elements (2), 'O'ring (3)
and spacer (4) .
• Retaining ring (1) and a snap ring (7) hold the lip seal
into position.
Double Lip Seal - Assembly
1. Make sure the shaft and pump body bores in the seal
area are thoroughly cleaned.
2. Coat the 'O'ring (9) in the underside of the shaft sleeve (6) with a thin layer of lubricant (supplied).
3. Gently slide the shaft sleeve (6) over the pump shaft and engage the pin from the sleeve into the
slot on the shaft.
4. Place 'O'ring (8) into pump body bore and coat it with a thin layer of lubricant.
5. Fit the housing plate assembly (5) into the pump body and on top of the 'O'ring (8). The flat side of
the housing plate should face towards the center of the pump.
6. Fill cavity between the two lips with a chemical resistant grease, Molykote FS-3451 or similar.
7. Tighten the capscrews to retain the housing plate (5) to the pump body.
8. When fitting pump body onto gear housing be very careful not to damage the lip seals with shaft
splines. A shaft protector (p/n 530041201) should be used to prevent spline damage to the seals.
6
5432 1
98 7
Item Description
1 Retaining Ring
2 Lip Seal Element
3 'O' ring
4 Spacer
5 Housing Plate
6 Shaft Sleeve
7 Snap Ring
8 'O' ring
9 'O' ring

Relief Valve - General
The diaphragm relief valve is integral with the front cover. It is supplied preset at 60psi and
cannot be adjusted.
Front Cover
Valve Housing
Fig. 11
Relief Valve - Disassembly
- Ensure the pump and drive are isolated from the power supply, and close isolating valves on
either side of the pump.
- Before dismantling, or carring out any work on relief valve, any residual pressure must be
released.
- To release the residual pressure, slacken the front cover nuts to allow product to drain from
the pump head.
- The valve and front cover may now be removed from the pump by removing the r-clips and
front cover nuts.
- Before removing the valve housing, the spring pressure must be released.
- To release the spring pressure, the valve housing nuts must be slackened carefully until they
turn easily by finger.
- The valve housing can now be removed from the front cover by removing the nuts and an-
chor plate. Acess is now gained to the diaphragm.
- The diaphragm should be inspected for damage and wear, and replaced if necessary.
- Assembly is reverse of disassembly.
- Valve housing nuts should be tightened to a torque of 22 lb.ft.
Page 20