Fristam Pumps FKL 15 Instructions for use

INSTRUCTION AND MAINTENANCE MANUAL:
FKL 15 AND 20 STYLE PUMP
Sanitary Positive Displacement Pump

Fristam Pumps
DESCRIPTION
This manual contains installation, operation and repair instructions for the Fristam FKL 15 & 20 Series bal-
anced circular piston pump.
The FKL pump is a positive displacement pump characterized by its balanced rotor design. The rotors travel
through a precisely machined, close clearance channel in the housing and cover allowing the product to be
pumped very efficiently.
The FKL 15 & 20 series pump features a unique balanced rotor design with heavy-duty shafts allowing the
pump to maintain its efficiency at differential pressures up to 200 psi. The pump also features rotors made
from “non-galling” stainless steel, which allows the pump to continue to run even under extreme conditions.
The FKL series pump is ideal for pumping products that are shear sensitive, have a high viscosity and/or con-
tain large particulate. The FKL series pump excels in applications with high differential pressure and/or low
inlet pressures and its high efficiency, low slip performance makes it an excellent pump for metering applica-
tions for consistent flow control.
The FKL series pump is available with any connection type desired and may be mounted with the inlet/outlet
connections in a horizontal or vertical orientation. The pump should be coupled to a motor/drive assembly
properly specified to give the desired performance for the required application.
CAUTION: BEGIN ALL PUMP MAINTENANCE OPERATIONS BY DISCONNECTING THE ENERGY SOURCE TO THE PUMP. OBSERVE ALL LOCK OUT/TAG
OUT PROCEDURES AS OUTLINED BY ANSI Z244.1-1982 AND OSHA 1910.147 TO PREVENT ACCIDENTAL START-UP AND INJURY.

FKL 15 & 20 Series Pump
TABLE OF CONTENTS
Technical Information..................................................................................................................................4
Installation ................................................................................................................................................ 5-8
Recommended Preventive Maintenance ......................................................................................................9
Mechanical Seal Assembly drawings ..........................................................................................................10
O-Ring Seal Assembly drawings .................................................................................................................11
Seal Part Numbers ......................................................................................................................................12
Exploded Pump Head Assembly .................................................................................................................13
Exploded Pump Gearbox Assembly ............................................................................................................14
Pump Head and Gearbox Part Numbers ....................................................................................................15
Pump Head Disassembly....................................................................................................................... 16-18
Pump Head Assembly & Seal Replacement ......................................................................................... 19-25
Pump Gearbox Disassembly ................................................................................................................. 26-29
Pump Gearbox Assembly & Shaft and/or Bearing Replacement ......................................................... 29-34
Setting the Rotor Gap........................................................................................................................... 32-33
Warranty......................................................................................................................................................36

Fristam Pumps
TECHNICAL INFORMATION
SPECIFICATIONS
Maximum Pressure Rating ............................................................................................................. 200 PSIG
Normal Speed Range.................................................................................................................0 to 600 RPM
Normal Temperature Differential (Standard Rotors) ......................................................................... Δ140°F
Normal Temperature Differential (High Temperature Rotors).......................................................... Δ210°F
STANDARD MATERIALS OF CONSTRUCTION (NOTE: OTHER OPTIONS AVAILABLE)
Product Contact Components ...............................................................................AISI 316L Stainless Steel
Rotors ................................................................................................................. Non-galling Stainless Steel
Seal Components
Stationary Seal ......................................................................................................................Carbon
Rotating Seal Material .................................................Chrome Oxide Coated 316L Stainless Steel
Product Contact Surfaces ......................................................................................................32μin Ra finish
Cover O-ring........................................................................................................................................... Buna
Seal O-rings............................................................................................................................................Viton
SEAL OPTIONS
Mechanical Seal Type.......................................................................................................... Single or Double
O-ring Seal Type .................................................................................................................Single or Double
RECOMMENDED TORQUE VALUES
Cover Nut ......................................................................................................................................... 65 in-lbs
Housing Screw ................................................................................................................................. 45 in-lbs
Rotor Bolt.......................................................................................................................................... 25 ft-lbs
Bearing Lock Nut.............................................................................................................................. 50 ft-lbs
Gearbox Nuts.................................................................................................................................... 45 in-lbs
Strap Screw ....................................................................................................................................... 10 ft-lbs
TOOLS FOR ASSEMBLY & DISASSEMBLY
6mm Socket .............................................................................................................................. Strap Screws
8mm Socket ...................................................................................................................Gearbox Cover Nuts
Gearbox Forcing Screws
10mm Socket .....................................................................................................................Pump Cover Nuts
19mm Socket ...............................................................................................................................Rotor Bolts
4mm Allen Wrench Socket ................................................................................................. Housing Screws
Bearing Cover Bolts
Ratchet .......................................................................................................................... For Loosening Bolts
Standard Screwdriver ................................................................................................... Bearing Lockwasher
M22 Spanner Wrench ......................................................................................................... Bearing Locknut
Torque Wrench ..................................................................................................For Proper Bolt Tightening
Adjustable Pliers.................................................................................... Removing & Installing Water Pipes
Soft-faced Hammer...................................................................................................... For Removing Shafts
1/2” Diameter Wooden Dowel................................................................Removing & Installing Rotor Bolts
Food Grade Lubricant…………………………………………… ........For Lubricating O-rings & Gaskets
LUBRICATION
Oil Grade ......................................................................................................................................SAE 15W40
Oil Capacity
Horizontal ................................................................................................ 0.6 liters / 0.63 US quarts

FKL 15 & 20 Series Pump
INSTALLATION
UNPACKING
Check the contents and all wrapping when unpacking the pump. Inspect the pump carefully for any damage
that may have occurred during shipping. Immediately report any damage to the carrier. Keep the protective
caps over the pump inlet and outlet in place until you are ready to install the pump.
INSTALLING
Prior to actually installing the pump, ensure that:
• The pump will be readily accessible for maintenance, inspection and cleaning.
• Adequate ventilation is provided for motor cooling.
• The drive and motor type is suitable for the environment where it is to be operated. Pumps intended for
use in hazardous environments e.g., explosive, corrosive, etc., must use a motor and drive with the
appropriate enclosure characteristics. Failure to use an appropriate motor type may result in serious
damage and/or injury.
• When switching the pump mounting to vertical, the sight glass and vent cap will need to be switched.
PIPING
CAUTION: Because the FKL pump is a highly efficient positive displacement pump, the user needs to ensure
that the pump will not be over-pressurized during operation as this can cause severe damage to the pump.
(Over-pressurization can occur if a valve is closed on the discharge of the pump and the pump continues to
run beyond its maximum pressure rating.) The pump warranty is void for damage caused by over-
pressurization. The pressure can be determined by putting a pressure gauge at the discharge side of the
pump.
Follow good piping practices when installing your FKL series pump:
• Support all piping independently to minimize the forces
exerted on the pump (figure 1).
• Ensure that the piping can accommodate thermal
expansion without stressing the pump.
• Slope inlet piping up to pump to avoid air pockets
(figure 2).
SUPPORTS
1265000242
REV. -
INLET
1265000243
REV. -
FIGURE 2
FIGURE 1

Fristam Pumps
• Avoid sump areas where sediment may
collect (figure 3).
• Use a check or “foot” valve on the inlet side
of the pump in lift applications to keep the
suction piping flooded.
• Avoid throttling valves in the suction piping.
• Keep suction lines as short and direct as
possible.
• Avoid abrupt transitions in the piping systems
(figure 4).
• Avoid the formation of air
pockets in the piping (figure 5).
• Ensure that the NPSH available
in the system is greater than
NPSH required by the pump.
• Avoid abrupt closure of shut-off
valves, this may cause hydraulic
shock which can cause severe
damage to the pump and
system.
• Avoid elbows in the suction line if possible. When
necessary they should be located 5 pipe diameters
away from the pump inlet and have a bend radius
greater then 2 pipe diameters (figure 6).
• Install a relief valve on the discharge side of the
pump with a bypass loop back to the suction side
to ensure that the pump cannot be over-
pressurized.
FIGURE 3
FIGURE 4
AIR
POCKET
FIGURE 5
5D
R>2D
FIGURE 6

FKL 15 & 20 Series Pump
ALIGNMENT
In most cases, the pump will be shipped with a drive unit mounted on a baseplate. The drive and pump are
aligned at the factory; however, this alignment should be checked after installation (Figure 7). Misalignment
between the pump and drive can result in premature bearing failure or other damage. If the pump is not
shipped with a drive unit, use a flexible coupling between the pump and drive unit. Align the pump and drive
unit according to the coupling requirements.
To check the alignment:
• Remove the wire ring from the coupling sleeve and let it hang between the sleeve and one of the flanges.
• To check the parallel alignment place a straight edge across the two coupling flanges and measure the
maximum offset at various points around the periphery of the coupling without rotating the coupling. If
the maximum offset (“A”) exceeds the figure shown under “Parallel” in the table below, realign the shafts.
• Check the angular alignment with a micrometer or caliper. Measure from the outside of one flange to the
outside of the other (“Y”) at intervals around the periphery of the coupling. Determine the maximum and
minimum dimensions without rotating the coupling. The difference between the maximum and
minimum must not exceed the figure given under “Angular” in the table below. If a correction is
necessary, be sure to recheck the parallel alignment.
• Reinstall the wire ring on the O.D. of the coupling sleeve.
WOODS SURE-FLEX COUPLING ALIGNMENT
AY
MAX.
Y
MIN.
PARALLEL ANGULAR
1265000238
REV.-
FIGURE 7
Parallel
AAngular Y max. - Y min. Y* Parallel AAngular Y max. - Y min. Y*
5
0.015" 0.056" 1.938" N/A N/A N/A
6
0.015" 0.070" 2.375" 0.010" 0.016" 2.375"
* The "Y" dimension is shown for reference.
Type E Type H
Sleeve
Size

Fristam Pumps
ELECTRICAL CONNECTIONS
Have an electrician connect the drive motor using sound electrical practices. Ensure that proper motor
overload protection is provided. The size of the drive selected should meet the requirements of the operating
conditions. A change in conditions (for example, higher viscosity product, higher product specific gravity)
can overload the motor. For technical assistance regarding operating condition changes, please contact
Fristam Pumps. Make sure that the pump is rotating in the correct direction.
WATER FLUSH CONNECTIONS
If your pump is equipped with a double mechanical or double o-
ring product seal, water must be supplied to provide cooling
and lubrication (Figure 8). Connect supply and return lines to
the water pipes supplied with the product seal on your pump.
The water pipes have a 1/16” NPT thread.
Note: Water should flow from bottom to top and steam should
travel top to bottom. Use about 3-12 gallons per hour of water
at 1-2 psi. Excessive seal pressure and/or flow rate through the
product seal cavity may cause increased seal wear and shorten
seal life.
START-UP CHECK-LIST
• Make sure that the pump and piping system are clear of
any foreign matter. Do not use the pump to flush the
system.
• Make sure that the pump and drive are properly
lubricated (page 4). See instructions from the
manufacturer for the drive.
• Check to make sure that all guards are in place and
secure.
• Check for proper pump and drive rotation (Figures 9 &
10). Make sure that the pump is flooded with product
when checking the rotation. Running the pump dry even
momentarily can cause seal damage.
• Check that all valves on the discharge side are open to
prevent over-pressurizing the pump.
• Place an inline screen before the pump inlet to ensure no
foreign objects run through the pump and alter critical
clearances.
FIGURE 8
SUCTION
(INLET)
DISCHARGE
(OUTLET)
1265000248
REV. -
FIGURE 10
FIGURE 9

FKL 15 & 20 Series Pump
RECOMMENDED PREVENTIVE MAINTENANCE
RECOMMENDED SEAL MAINTENANCE
• Visually inspect mechancical seal daily for leakage.
• Replace mechanical seal annually under normal duty.
• Replace mechanical seal as often as required under heavy duty.
ELASTOMER INSPECTION
Inspect all elastomers (o-rings and gaskets) when performing pump maintenance. We recommend replacing
elastomers during seal, pump shaft and/or motor replacement or sooner depending on the application.
LUBRICATION
The oil level should be maintained in the center of the sight glass on the side of the gearbox. The oil should
be changed every 4,000 hours under normal conditions and every 2,000 hours under severe conditions such
as washdown applications.
PERIODIC MAINTENANCE
Periodically inspect the pump housing, cover and rotors for any signs of wear or damage. If wear is present
this could be a sign of over-pressurization, incorrect rotor gap or bearing wear.
CLEANING RECOMMENDATIONS
When you are running products or cleaning solutions with different temperatures, you need to allow enough
time for all of the wetted components inside the pump to reach a steady-state temperature before you start
the pump. If your process does not allow you to stop the pump during this transition, you need to install
rotors that provide larger clearances. Note: that the clearances inside the FKL pump are extremely small.
If the rotor bolt o-ring, rotor washer o-ring, or rotor o-ring, the threaded hole on the end of the shaft will
need to be cleaned. We recommend removing the rotors and rotor bolts/washers while the pump is being
CIP’d. This will ensure that the internal threads are cleaned before production resumes.
If the process lines are to be cleaned with the pump, use a by-pass loop around the pump during the CIP
mode to maintain pipe velocity. Once the wetted components are at a steady temperature, the pump can be
started and run around 100 RPM with a backpressure of at least 10 PSI. As the product viscosity increases,
the required backpressure may need to be increased as well.

Fristam Pumps
SINGLE MECHANICAL SEAL ASSEMBLY
Rotating
Seal O-Ring
Rotor Bolt
O-Ring
Single
Stationary Seal
Single Seal
Spring
Single Stationary
Seal O-Ring
Rotor O-Ring
Rotor Cap
O-Ring
DOUBLE MECHANICAL SEAL ASSEMBLY
Rotating
Seal O-Ring
Rotor Bolt
O-Ring
Single Seal
Spring
Single Stationary
Seal O-Ring
Rotor O-Ring
Rotor Cap
O-Ring
Rotating Seal
Single
Stationary Seal
Rotating Seal
Double
Stationary Seal
Double Stationary
Seal O-Ring
Double Seal
Spring

FKL 15 & 20 Series Pump
SINGLE O-RING SEAL ASSEMBLY
Rotating
Seal O-Ring
Rotor Bolt
O-Ring
Single
O-Ring Seal
Single Stationary
Seal O-Ring
Rotor O-Ring
Rotor Cap
O-Ring
DOUBLE O-RING SEAL ASSEMBLY
O-Ring
Seal O-Ring
Rotating
Seal O-Ring
Rotor Bolt
O-Ring
Double
O-Ring Seal
Single Stationary
Seal O-Ring
Rotor O-Ring
Rotor Cap
O-Ring
O-Ring
Seal O-Ring
Double Stationary
Seal O-Ring

Fristam Pumps
Description Material Qty Part No. Description Material Qty Part No.
Viton 1180000085 Viton 1180000085
EPDM 1180000188 EPDM 1180000188
Viton 1180000700 Viton 1180000700
EPDM 1180000706 EPDM 1180000706
Viton 1180000700 Viton 1180000700
EPDM 1180000706 EPDM 1180000706
Single Seal Spring - 2 1820000041 Single Seal Spring - 2 1820000041
Carbon 1815600115 Carbon 1815600115
Silicon Carbide 1815600116 Silicon Carbide 1815600116
Viton 1180000261 Viton 1180000261
EPDM 1180000262 EPDM 1180000262
Chrome Oxide/SS 1810600112 Double Seal Spring - 2 1820000063
Silicon Carbide 1810600113 Double Stationary Seal Carbon 2 1815600117
Viton 1180000700 Viton 1180000701
EPDM 1180000706 EPDM 1180000707
Chrome Oxide/SS 1810600112
Silicon Carbide 1810600113
Viton 1180000700
EPDM 1180000706
Description Material Qty Part No. Description Material Qty Part No.
Viton 1180000085 Viton 1180000085
EPDM 1180000188 EPDM 1180000188
Viton 1180000700 Viton 1180000700
EPDM 1180000706 EPDM 1180000706
Viton 1180000700 Viton 1180000700
EPDM 1180000706 EPDM 1180000706
Viton 1180000350 Viton 1180000350
EPDM 1180000076 EPDM 1180000076
Viton 1180000261 Viton 1180000261
EPDM 1180000262 EPDM 1180000262
Single O-Ring Seal SS 2 1224000104 Double O-Ring Seal SS 2 1224000105
Viton 1180000700 Viton 1180000701
EPDM 1180000706 EPDM 1180000707
Viton 1180000700
EPDM 1180000706
2
2
2
2
2
Rotating Seal O-Ring
Rotor Cap O-Ring
Rotor O-Ring
Rotating Seal O-Ring
Single Stationary
Seal O-Ring
O-Ring Seal O-Ring O-Ring Seal O-Ring
Single Stationary
Seal O-Ring
Double Stationary
Seal O-Ring
2
Rotor Bolt O-Ring Rotor Bolt O-Ring
Double O-Ring Seal
2
2
2
2
Single Stationary
Seal O-Ring
Rotating Seal
Rotating Seal O-Ring
Rotor Bolt O-Ring
Rotor Cap O-Ring
Rotor O-Ring
Single Stationary Seal
Single Stationary
Seal O-Ring
Rotor Bolt O-Ring
Rotor Cap O-Ring
Rotor O-Ring
Single Stationary Seal
Single Mechanical Seal
2
2
2
2
2
2
Double Stationary
Seal O-Ring
2
Rotor Cap O-Ring
Rotor O-Ring
Rotating Seal
Rotating Seal O-Ring
2
2
Single O-Ring Seal
Double Mechanical Seal
2
2
2
2
2
2
2
2
2

FKL 15 & 20 Series Pump
Rotor
Key
Housing
Water Pipe
Rotating Seal
O-Ring
Double Stationary SealO-Ring
Single Stationary
SealO-Ring
Rotor O-Ring
Rotor Cap O-Ring
Rotor Bolt O-Ring
Rotating Seal
Single Stationary
Seal
Single Seal
Spring
Double Stationary Seal
Housing
Screw
Rotor
Rotor
Cap
Rotor
Bolt
Cover
Forcing
Screw
Cover
Nut
Cover O-Ring
Double SealSpring
Pin
Seal
Pin
Mechanical Seals
Double Stationary SealO-Rin
g
Double O-Ring Sea
Rotating Seal O-Ring
Single O-Ring Seal
Single Stationary
Seal O-Ring
O-Ring
SealO-Ring
O-Ring Seals
Exploded Pump
HeadAssembly

Fristam Pumps
Bearing
Locknut
Outer Bearing Spacer
Gearbox
Gasket
Bearing Cap
Front Bearing
Idle Shaft
Rear Bearing
Bearing
Lockwasher
Coupling
Key
Gear
Key
Drive
Shaft
Gearbox
Back
Guard
Gearbox Nut
Strap Bolt
Exploded Pump
Gearbox Assembly
Guar
d
Screw
Housing
Stud Strap
Pin
Vent
Cap
Strap Bolt
Strap
Gapping Shims
Inner Bearing
Spacer Gear
Spacer
Front Bearing
Bearing
Cap Bolt
Gear
Oil Drain Plug
Gear Spacer
Front
Oil Seal
Rear
Oil Seal
Shaft Hole Plug
Gearbox Forcing Screw
Sight Glass
Gearbox Front
Pin
Gearbox Stud

FKL 15 & 20 Series Pump
15 20 15 20
Forcing Screw - 2 Oil Sight Glass 1
Cover Nut - 4 Gearbox Front 1 Cover - 1 1652620000 1654620000 Front Oil Seal 2
Buna 1180000000 1180000716 Gapping Shim (1mm) 4** Viton 1180000149 1180000215 Gapping Shim (0.5mm) 2**
EPDM 1180000299 1180000300 Gapping Shim (0.25mm) 0**
Pin - 6 Gapping Shim (0.05mm) 0**
Rotor Bolt - 2 Drive Shaft 1 1372600028 1372600026
Viton Idle Shaft 1 1372600029 1372600027
EPDM Gear Key 2
Rotor Cap - 2 Coupling Key 1
Viton Front Bearing Assembly 2
EPDM Gear Spacer 4
Rotor (standard) - 2 1653630000 1655630000 Bearing Cover 2
Viton Bearing Cover Bolt 8
EPDM Gear 2
Housing Screw - 2 Rear Bearing 2 Housing - 1 1652610000 1654610000 Bearing Lockwasher 2 Seal Pin - 4* Bearing Locknut 2
Water Pipe - 2 Gearbox Gasket 1
Rotor Key - 2 1315000040 1315000038 Rear Oil Seal 1 Guard - 1 Shaft Hole Plug 1 Guard Screw - 1 Gearbox Back 1 Housing Stud - 4 Gearbox Forcing Screw 2
Vent Cap - 1 Gearbox Nut 4
Strap - 2 Oil Drain Plug 1 Strap Bolt - 4 Oil Drain Plug 1
1812000041 1812000042
Cover O-Ring Rotor Bolt O-Ring Rotor Cap O-Ring Rotor O-Ring
1 2
*Qty = 0 in o-ring seals **Quantities may vary
1248002601
1373000068 1373000069 1373000070
1315000037 1315000039
2 21180000700
1180000085
1180000188
1104000068
1180000706
Description Qty
1103004836 1018000045
Part No.
Material
1891000050 1102000001 1936000137 1102000000 1180000700 1248000023
1180000706
1101000209 1891000051 1910000002
1173000041 1224000103 1304000017 1101000208 1101000218 1103000080 1248000012 1306000083 1181000152 1173000039 1104000069 1310600149 1812000040
1373000067
1925000009 1248000012
Description Qty Part No.
1310600150
1103000079 1101000210
1365000012

Fristam Pumps
FIGURE 11
Remove the cover nuts.
Remove the cover by turning the forcing
screws clockwise.
Remove the cover and discard the cover o-
ring.
Jacket Cover Only: Remove cover nuts, then
remove jacketed cover and jacketed cover o-
ring. Remove cover and discard cover o-ring.
PUMP HEAD DISASSEMBLY
FIGURE 12
Place a 1/2” diameter wooden dowel between
the rotors.
Wooden
Dowel
FIGURE 13
Remove the rotor bolts.
Discard the rotor bolt o-rings.
Remove the rotor caps and discard the rotor
cap o-rings.
Remove the rotors. Note: Keep rotors free
from damage (i.e. nicks, dings) to ensure
high efficiency the pump was designed for.
Discard the rotor o-rings.
Remove the rotor keys.
Place the Dowel
here to loosen the
Top Rotor Bolt
Place the Dowel
here to loosen the
Bottom Rotor

FKL 15 & 20 Series Pump
FIGURE 14
Remove the housing screws .
Carefully slide the housing forward and remove.
Note: Keep housing free from damage, e.g.,
nicks and dings, to ensure high efficiency the
pump was designed for.
FIGURE 15
Place the housing face down.
Remove and discard the single stationary
seals, o-rings and springs.
Double Seal Only: Remove and discard the
double stationary seals, o-rings and springs.
MECHANICAL SEAL DISASSEMBLY
Double
Mechanical
Seal
Single
Mechanical Seal
Components
For O-Ring Seal disassembly - skip to Figures 17.

Fristam Pumps
O-RING SEAL DISASSEMBLY
FIGURE 17
Place the housing face down.
Remove and discard the single o-ring seals
and o-rings.
Double Seal Only: Remove and discard the
double o-ring seals and o-rings.
Single O-Ring
Seal Compo-
Double O-Ring
Seal Components
FIGURE 16
Remove and discard the rotating seals and
o-rings.

FKL 15 & 20 Series Pump
FIGURE 18
Install the single stationary seal o-rings.
Install the single seal springs making sure to
align the seal pins on the housing with the cut-
outs on the springs.
MECHANICAL SEAL ASSEMBLY
Single Stationary
Seal O-ring
Seal Pins
FIGURE 19
Install the single stationary seals mak-
ing sure to align the seal pins on the
housing with the cut-outs on the seals.
Seal Pins
Note: The housing, rotors and cover should be cleaned before reassembly.
For O-Ring Seal assembly - skip to Figures 23-24.
Lubricate

Fristam Pumps
FIGURE 20
Double Seal Only: Install the
double stationary seal o-rings.
Install the double seal springs
making sure to align the seal
pins on the housing with the
cut-outs on the springs.
Double Stationary
SealO-ring
Seal Pins
FIGURE 21
Double Seal Only: Install the dou-
ble stationary seals making sure to
align the seal pins on the housing
with the cut-outs on the seals.
Align pin
with grooves Lubricate