Fristam Pumps FKL-25 Instructions for use

FKL Series Pump
1
INSTRUCTION AND MAINTENANCE MANUAL:
FKL-25, 50, 75, 150, 250 AND 400 STyLE PUMP
SANITARy POSITIVE DISPLACEMENT PUMP

Fristam Pumps
2
DESCRIPTION
This manual contains installation, operation and repair instructions for the Fristam FKL 15, 20, 25, 50,
75, 150, 250 and 400 Series balanced 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 series pump features a unique balanced rotor design with heavy-duty shafts allowing the
pump to maintain its efficiency at differential pressures up to 300 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 contain 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 applications for consistent flow control.
The FKL series pump is available with any connection type desired and may be mounted with the in-
let/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 ACCIDEN-
TAL START UP AND INJURY.

FKL Series Pump
3
TAbLE OF CONTENTS
RefeRence MateRial .......................................................................................... 4-6
technical infoRMation .....................................................................................4
coupling alignMent and RecoMMended toRque Values tables..........................5
fKl RotoR cleaRances....................................................................................6
installation ....................................................................................................... 7-9
RecoMMended pReVentiVe Maintenance ................................................................10
cleaning RecoMMendations ............................................................................10
seal ReplaceMent .......................................................................................... 11-17
puMp end disasseMbly ............................................................................. 11-12
Mechanical seal caRtRidge ReMoVal..............................................................13
disasseMbly of seal caRtRidge foR Mechanical seals ....................................13
asseMbly of seal caRtRidge foR Mechanical seals ........................................14
seal caRtRidge installation ..........................................................................14
seal disasseMbly foR o-Ring seals ................................................................15
seal asseMbly foR o-Ring seals.....................................................................15
puMp end asseMbly .................................................................................. 16-17
beaRing and/oR shaft ReplaceMent (fKl 25, 75, 150, 250 & 400) ............... 18-23
geaRbox disasseMbly ............................................................................... 18-19
geaRbox asseMbly..........................................................................................19
setting the RotoR gap .................................................................................. 19-20
install the geaRbox ...................................................................................... 21-22
beaRing and/oR shaft ReplaceMent (fKl50) ................................................. 24-29
geaRbox disasseMbly .....................................................................................24
geaRbox asseMbly.................................................................................... 25-26
install the geaRbox ...................................................................................... 26-28
setting the RotoR gap ........................................................................................29
fKl exploded View dRawing (fKl 25, 75, 150, 250 & 400) ........................ 30-31
fKl paRt nuMbeRs (fKl 25, 75, 150, 250 & 400) ....................................... 32-36
fKl 50 exploded View dRawing .................................................................... 38-39
fKl 50 paRt nuMbeRs .........................................................................................40
single Mechanical seal dRawing .........................................................................41
double Mechanical seal dRawing........................................................................42
aseptic double Mechanical seal dRawing ...........................................................43
single and double o-Ring seal dRawings ............................................................44
fKl seal paRt nuMbeRs ................................................................................ 45-50
fKl aseptic and JacKeted coVeR options infoRMation .........................................51
tRoubleshooting..................................................................................................52
notice of teRMs, waRRanty pRoVisions including
disclaiMeRs, claiMs and liMitation of liability .................................................55

Fristam Pumps
4
REFERENCE MATERIAL
TEChNICAL INFORMATION
SPECIFICATIONS
Normal Differential Pressure Range......................................................................... 0 to 300 PSI
Normal Speed Range ............................................................................................... 0 to 600 RPM
Normal Temperature Differential (Standard Rotors)........................................................∆140°F
Normal Temperature Differential (High Temperature Rotors)........................................ ∆210°F
MATERIALS OF CONSTRUCTION
Major Product Contact Components ...............................................................AISI 316L (CF3M)
Rotors................................................................................................. Non-galling Stainless Steel
Cover Gasket.......................................................................................................BUNA (standard)
Also available in ...................................Viton, EPDM and other options available
Surface Finish for Product Contact Surfaces.................................................... 32 Ra (standard)
Also available in ........................................................................... 25 Ra and 20 Ra
Cover Gasket and Other O-rings on Aseptic....................................................................... EPDM
ShAFT SEALS & O-RINgS
Mechanical Seal Type ............................................................................................. Single/Double
Stationary Seal Ring Material ..........................................................................Carbon (standard)
Also available in ...........................................Silicon Carbide & Chrome oxide/SS
Rotating Seal Ring Material ............................................................................. Chrome Oxide/SS
Also available in ............................................................................ Silicon Carbide
Other O-rings (mechanical seals) .......................................................................Viton (standard)
Also available in ..............................................EPDM and other options available
O-ring Seal Type ..................................................................................................... Single/Double
O-ring Seal Material ............................................................................................Viton (standard)
Also available in ..................................... EPDM and other availableupon request
Note: o-ring seal not available on the FKL 400
LUbRICATION
Oil Grade..................................................................................................................... SAE 15W40
Oil Capacity - Horizontal
FKL 25 .......................................................................................... 1.66 liters (1.75 US quarts)
FKL 50 .............................................................................................. 1.4 liters (1.5 US quarts)
FKL 75 .............................................................................................. 4.2 liters (4.5 US quarts)
FKL 150 ............................................................................................ 7.1 liters (7.5 US quarts)
FKL 250 ........................................................................................... 10.4 liters (11 US quarts)
FKL 400 ........................................................................................ 17.5 liters (18.5 US quarts)
Oil Capacity - Vertical
FKL 25 .......................................................................................... 0.65 liters (0.75 US quarts)
FKL 50 .............................................................................................. 1.4 liters (1.5 US quarts)
FKL 75 ........................................................................................... 2.6 liters (2.75 US quarts)
FKL 150 .......................................................................................... 3.9 liters (4.25 US quarts)
FKL 250 ............................................................................................ 4.2 liters (4.5 US quarts)
FKL 400 ............................................................................................ 8.0 liters (8.5 US quarts)

FKL Series Pump
5
Woods Sure-Flex Coupling Alignment
Sleeve
Size
Type E Type H
Parallel
A
Angular
Y max. - Y
min.
Y* Parallel
A
Angular
Y max. - Y
min.
Y*
5 .015 .056 1.938 - - -
6 .015 .070 2.375 .010 .016 2.375
7 .020 .081 2.563 .012 .020 2.563
8 .020 .094 2.938 .015 .025 2.938
9 .025 .109 3.500 .017 .028 3.500
10 .025 .128 4.063 .202 .032 4.063
11 .032 .151 4.875 .022 .037 4.875
12 .032 .175 5.688 .025 .042 5.688
13 .040 .195 6.688 .030 .050 6.688
14 .045 .242 7.750 .035 .060 7.750
Dimensions are in inches.
*The “Y” dimension is shown for reference.
Recommended Torque Values
Part FKL 25 FKL 50 FKL 75 FKL 150 FKL 250 FKL 400
Cover Nut 15 ft-lb 45 ft-lb
Rotor Bolt 25 ft-lb 50 ft-lb 65 ft-lb
Bearing Cap Screw 60 in-lb 10 ft-lb 25 ft-lb
Bearing Lock Nut 50 ft-lb 7 in-lb* 50 ft-lb
Housing Hex Head Bolt 60 in-lb 10 ft-lb 45 ft-lb
Gearbox Cover Bolt 10 ft-lb 20 ft-lb
Mounting Strap Screw 10 ft-lb 70 ft-lb 80 ft-lb
Seal Housing Screw 30 in-lb 10 ft-lb
Housing Socket Head Screw n/a 10 ft-lb n/a
*The torque on the FKL 50 Bearing Lock Nut is a rotating torque for the shaft without the oil seals in
place.

Fristam Pumps
6
TAbLE A3: FKL ROTOR CLEARANCES
Model Standard Rotors High Temperature Rotors
Back Face Radial Front Face Back Face Radial Front Face
25 0.06-0.08
(0.0024-0.0031”)
0.05-0.09
(0.002-0.0035”)
0.07-0.17
(0.0028-0.007”)
0.11-0.12
(0.0039-0.0047”)
0.08-0.12
(0.0031-0.0047”)
0.13-0.23
(0.0051-0.0091”)
50 0.07-0.11
(0.0028-0.0043”)
0.055-0.105
(0.0022-0.0041”)
0.08-0.20
(0.0031-0.0079”)
0.11-0.15
(0.0043-0.0059”)
0.095-0.145
(0.0037-0.0057”)
0.15-0.27
(0.0059-0.0106”)
75 0.08-0.12
(0.0031-0.0047”)
0.075-0.125
(0.003-0.0049”)
0.10-0.22
(0.0039-0.0087”)
0.12-0.16
(0.0047-0.0063”)
0.125-0.175
(0.0049-0.0069”)
0.18-0.30
(0.0071-0.0118”)
150 0.08-0.12
(0.0031-0.0047”)
0.085-0.135
(0.0033-0.0053”)
0.13-0.25
(0.0051-0.0098”)
0.13-0.17
(0.0051-0.0067”)
0.135-0.185
(0.0053-0.0073”)
0.22-0.34
(0.0087-0.0134”)
250 0.09-0.13
(0.0035-0.0051”)
0.110-0.170
(0.002-0.0067”)
0.16-0.28
(0.0063-0.011”)
0.14-0.18
(0.0055-0.0071”)
0.18-0.24
(0.0071-0.0094”)
0.27-0.39
(0.0106-0.0154”)
400 0.10-0.14
(0.0039-0.0055”)
0.120-0.180
(0.0047-0.0071”)
0.16-0.30
(0.0063-0.0118”)
0.16-0.20
(0.0063-0.0079”)
0.20-0.26
(0.0079-0.0102”)
0.27-0.41
(0.0106-0.0161”)
Chocolate Rotors
25 0.24-0.26
(0.0094-0.0102”)
0.229-0.279
(0.009-0.011”)
0.265-0.345
(0.0104-0.0136”)
50 0.28-0.32
(0.011-0.0126”)
0.293-0.343
(0.0115-0.0135”)
0.316-0.396
(0.0124-0.0156”)
75 0.28-0.32
(0.011-0.0126”)
0.293-0.343
(0.0115-0.0135”)
0.316-0.396
(0.0124-0.0156”)
150 0.31-0.35
(0.0122-0.0138”)
0.305-0.355
(0.012-0.014”)
0.341-0.421
(0.0134-0.0166”)
250 0.33-0.37
(0.013-0.0146”)
0.380-0.440
(0.015-0.0173”)
0.380-0.460
(0.015-0.0181”)
400 0.36-0.40
(0.0142-0.0157”)
0.453-0.513
(0.0178-0.0202”)
0.407-0.507
(0.016-0.020”)
Dimensions are in millimeters (inches).

FKL Series Pump
7
INSTALLATION
UNPACKINg
Check the contents and all wrapping when unpacking the pump. Carefully inspect for any damage that
may have occurred during shipping. Immediately report any damage to the carrier. Leave the protec-
tive caps over the pump inlet and outlet connections 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 intend-
ed 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 from top drive shaft to bottom drive shaft, or visa versa, the gear cover
needs to be rotated 180 degrees. This will move the drain plug, and sight glass to the appropriate
positions.
• 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 differential pressure rating.) The pump warranty
is void for damage caused by over-pressurization. The differential
pressure can be determined by putting a pressure gauge at the
discharge side of the pump and a pressure gauge at the inlet side of
the pump and calculating the difference.
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).
•Avoid sump areas where sediment may collect
(Figure 3).
•Use a check or “foot” valve on the in-
let side of the pump in lift applications
to keep the suction piping flooded.
• Avoid throttling valves in the suction
piping.
INLET
IL-0517
Figure 2
SUPPORTS
IL-0516
Figure 1
Figure 3

Fristam Pumps
8
• 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 neces-
sary they should be located
5 pipe diameters away from
the pump inlet and have a
bend radius greater then 2 pipe diam-
eters (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.
ALIgNMENT
In most cases, the pump will be shipped
with a drive unit mounted on a com-
mon baseplate. The drive and pump
are aligned at the factory; however, this
alignment should be checked after instal-
lation (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.
ChECKINg 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 exceeds the figure shown under
“Parallel” in Table A1 (page 53), realign the shafts.
Check the angular alignment with a micrometer or caliper. Mea-
sure from the outside of one flange to the outside of the other
(“Y”) at intervals around the periphery of the coupling. Deter-
mine the maximum and minimum dimensions without rotating
the coupling. The difference between the maximum and mini-
mum must not exceed the figure given under “Angular” in Table
A1 (page 53). If a correction is necessary, be sure to recheck the
parallel alignment.
Reinstall the wire ring on the O.D. of the coupling sleeve.
5D
R>2D
Figure 6
AIR
POCKET
Figure 5
Figure 4
Figure 7

FKL Series Pump
9
ELECTRICAL CONNECTIONS
Have an electrician connect the drive motor using sound electrical practices. Ensure that proper mo-
tor 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 chang-
es, 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 cool-
ing and lubrication. 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. See Figure 8 for
the proper orientation. 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
1. Make sure that the pump and piping system are clear
of any foreign matter. Do not use the pump to flush the
system.
2. Make sure that the pump and drive are properly lubricated. Check the lubrication section (page 52)
in this manual for the pump. See instructions from the manufacturer for the drive.
3. Check to make sure that all guards are in place and secure.
4. Check for proper pump and drive rotation (Figure 9). Make sure that the pump is flooded with
product when checking the rotation. Running the pump dry even momentarily can cause seal dam-
age.
5. Check that all valves on the discharge side are open to prevent over-pressurizing the pump.
RECOMMENDED PREVENTIVE MAINTENANCE
RECOMMENDED SEAL MAINTENANCE
Visually inspect the mechanical seal regularly for leakage.
Annually replace mechanical seal under normal condi-
tions.
Replace mechanical seal as often as required under severe
conditions (abrasive product, dry running, etc.).
ELASTOMER INSPECTION
Inspect all elastomers when performing pump mainte-
nance. We recommend replacing elastomers (o-rings and
gaskets) during seal replacements or every 3 months,
whichever comes first.
LUbRICATION
The bearings and gears are lubricated with 15W40
oil. The oil level should be maintained in the center
of the sight glass on the side of the gearbox housing.
The oil should be changed every 4,000 hours under
normal conditions and every 2,000 hours under severe conditions such as washdown applications.
RETURN
WATER PIPE
SUPPLY
WATER PIPE
1265000235
8/5/05
Figure 8
SUCTION
(INLET)
DISCHARGE
(OUTLET)
IL-0519
4/16/01
Figure 9

Fristam Pumps
10
See the oil capacity listing on page 52.
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.
TEMPERATURE DIFFERNTIALS
Positive pump efficiency depends on internal clearances between the rotors and the pump housing. The
pump can withstand certain temperature changes based on the rotors. For example, if you are running
CIP solution at 180°F and your product is 50°F, that is a 130°F temperature differential. This differen-
tial is in the standard rotor range.
The temperature differential is a concern, because if there is a severe temperature change in the pump,
the shaft and rotors may expand inside the pump housing. This expansion can result in rotor to cover
or rotor to housing damage.
The clearances inside the FKL pump are extremely small, below are the recommended temperature
differentials.
FKL Temperature Differential Correct Rotor
∆140°F standard rotors
∆210°F high temperature rotors
Fristam recommends high temperature rotors for pumps that will be cleaned or steamed at elevated
temperatures.
CLEANNINg RECOMMENDATIONS FOR FKL PUMPS:
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.
Due to the use of a rotor bolt additional cleaning may be necessary if there is an o-ring failure. If one
of the following fail, 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.
SEAL REPLACEMENT
CAUTION! Begin all pump maintenance 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.
TOOLS REqUIRED FOR SEAL REPLACEMENT:
Soft-faced hammer
Screwdriver (flat blade)
1” diameter wooden dowel
4 mm Allen wrench
6 mm Allen wrench (FKL 400 only)
Torque wrench

FKL Series Pump
11
!
! WARNINg
Seal assembly tool or a press (part number 1018000011)
TOOLS REqUIRED FOR SPECIFIC PUMP MODEL (WRENCh SIzE IN MM):
FKL 25 FKL 50 FKL 75 FKL 150 FKL 250 FKL 400
cover nuts 13 mm 19 mm 19 mm 19 mm 19 mm 19 mm
rotor bolt 19 mm 19 mm 19 mm 24 mm 32 mm 32 mm
housing bolts 10 mm 13 mm 19 mm 19 mm 19 mm 19 mm
Note: the reference numbers listed in the text (#) refer to the assembly drawing on pages 30-31, seal
assembly drawings on pages 41-44 and the parts list on page 32-36 and 45-50.
PUMP hEAD DISASSEMbLy
Drain all product from the pump head prior to disassembly. The pump head may be isolated with inlet
and outlet valves. Disconnect the suction and discharge piping from the pump. Disconnect the seal
flush supply and return lines to your pump if the pump is equipped with a double mechanical or double
o-ring product seal.
REMOVE ThE COVER
a) Loosen and remove the cover nuts and cover nut washers with the appropriate wrench.
b) Remove the cover by turning the two forcing screws clockwise.
c) Remove the cover o-ring.
For Jacketed Cover - start with instruction A and then remove the jacketed cover, jacketed cover o-
ring and then continue with instructions B and C.
REMOVE ThE ROTORS
a) To loosen the first rotor, place the wooden dowel between the rotors as shown in Figure 10.
b) Turn the first rotor bolt counter-clockwise with the appropriate wrench.
c) Remove the rotor bolt and rotor cap with o-rings from the first rotor.
d) Repeat instructions a - c for the second rotor.
e) The rotors and rotor o-rings can now be removed from the pump housing by
pulling straight out as shown in Figure 11. Handle the rotors with care to avoid
damage.
Inspect the rotors and pump housing for signs of wear. If wear is present, see the trouble-shooting
guide (page 52) for possible solutions.
REMOVE ThE PUMP hOUSINg
a) Loosen the hex head housing bolts with the appropriate wrench.
b) Now carefully pull the pump housing away from the gearbox as shown in Figure 12. You may need to
alternately tap on the sides of the pump housing
near the inlet and outlet ports with the soft face
hammer until the housing pins separate from the
gearbox.
You are now ready to remove the seal components
from the pump housing.
MEChANICAL SEAL CARTRIDgE REMOVAL
a) Place the pump housing face down as shown in
Figure 13.
b) Loosen the seal housing screws with the 4 mm
Allen wrench.
IL-0521
Figure 10

Fristam Pumps
12
c) Remove the seal housing screws,
seal cartridges and seal housing
o-rings as shown in Figure 13.
d) Remove the two rotating seal
rings and rotating seal o-rings
from the pump shaft.
If replacing the cartridge with a
new cartridge proceed to the ‘Seal
Cartridge Installation’ section on
page 14.
DISASSEMbLy OF SEAL CARTRIDgE FOR
MEChANICAL SEALS
Place all of the seal parts on a clean
work area and disassemble one car-
tridge at a time.
a) Place the seal cartridge, with the
seal face up, onto the seal assem-
IL-0522
Figure 11
IL-0526
Figure 12

FKL Series Pump
13
bly tool or press.
b) Insert the seal compressor disc onto the seal face.
c) Use the seal assembly tool to compress the seal
so that all of the pressure is off the seal retaining
ring.
d) Use the flat-faced screwdriver to pry the seal re-
taining ring out of the seal housing.
e) Remove the seal cartridge from the seal assembly
tool.
f) Use your fingers to gently press the seal elements
out of the seal housing.
g) Remove the outer and inner seal springs and the
outer stationary seal o-ring.
h) The seal housing should be cleaned to prepare it
for reassembly.
ASSEMbLy OF SEAL CARTRIDgE
Assemble the cartridges one at a time.
a) Lubricate the new outer stationary seal o-ring and slightly stretch.
b) Fit the outer stationary seal o-ring into its groove
inside the seal housing.
c) Place the inner and outer seal springs into the seal
housing.
d) Set the seal housing on the seal assembly tool.
e) Place the new inner stationary seal into the seal
housing.
f) Single mechanical seal: Lubricate the outer edge
of the single seal insert and place into the seal
housing. Be sure to fit the notches around the
pins.
Double mechanical seal: Lubricate the outer edge
of the outer stationary seal and place into the seal
housing. Be sure to fit the notches around the
←Double and Aseptic seals only
←Aseptic seals only
Figure 13
SINGLE SEAL INSERT
(OUTER STATIONARY SEAL)
SEAL RETAINING RING
INNER STATIONARY SEAL RING
SEAL PIN
SEAL HOUSING
1265000161
6/4/04
Figure 14

Fristam Pumps
14
pins.
g) Set the seal retaining ring on top of the seal hous-
ing.
h) Push down on the outer stationary seal until it is
past the seal retaining ring groove.
i) Use your fingers to fit the seal retaining ring into
place.
SEAL CARTRIDgE INSTALLATION
a) Place the pump housing face down as shown in
Figure 15.
b) Install the new inner stationary seal o-rings into
the grooves in the seal housing.
c) Install the seal housing o-rings into the new seal
cartridges.
d) Install one of the new seal cartridges onto the
pump housing with the flat side toward the
middle as shown.
e) Insert the seal housing screws through the holes
in the seal cartridges and tighten with the appropriate Allen wrench.
f) Double mechanical seal only, place the new small seal housing o-ring into the groove on the secured
seal cartridge.
g) Install the other new seal cartridge onto the pump housing by repeating instructions d and e.
g) Next lubricate and install the two
new rotating seal o-rings into the
first groove on the pump shaft as
shown in Figure 16. Aseptic seal
only, lubricate and install the four
rotating seal o-rings.
i) Finally, install the two new rotating
seal rings onto the shaft. The rotat-
ing seal ring will fit into the grooves
on the shaft and interlock with the
shaft. If you can rotate the seal ring,
it is not properly seated.
SEAL DISASSEMbLy FOR O-RINg SEALS
a) Place the pump housing face down
as shown.
b) Loosen the seal housing screws with
the 4 mm Allen wrench.
c) Remove the seal housing screws,
o-ring seal cartridges and inner o-
rings as shown in Figure 17.
d) Remove the seal o-rings from the seal housings with the flat screwdriver.
Inspect the pump shafts in the area in which the o-ring seals ride. Clean any o-ring or product residue
off the pump shafts. If the shafts are worn excessively they must be replaced.
You are now ready to install the new seal components.
←Double and Aseptic seals only
←Aseptic seals only
Figure 15
Figure 16
↑
Aseptic seals only
←Aseptic seals only

FKL Series Pump
15
SEAL ASSEMbLy FOR O-RINg SEALS
a) Place the pump housing face down as shown in Fig-
ure 17.
b) Install the new inner stationary seal o-rings into the
grooves in the seal housing.
c) Install the new seal o-rings into the o-ring seal hous-
ings. Do not lubricate the o-rings before installing.
d) Install one of the seal housings onto the pump hous-
ing with the flat side toward the middle as shown.
e) Insert the seal housing screws through the holes in
the o-ring seal housing and thread into the pump
housing. Tighten with the appropriate Allen wrench.
f) Double o-ring seals only, place the new small seal
housing o-ring into the groove on the secured o-ring
seal housing.
g) Install the other o-ring seal housing onto the pump
housing by repeating instructions e and f.
h) Lubricate the pump shafts with a food grade lubricant
compatible with the o-rings. Lubricate the shafts where the o-rings will slide.
i) You are now ready to install the pump housing onto the gearbox. Install the pump housing while
slowly rotating the shaft.
PUMP hEAD ASSEMbLy
Note: Any debris between the gearbox and housing will affect the gap. Make sure the gearbox front face
and pump housing surfaces are clean.
a) Carefully slide the pump housing over the pump shafts and onto the gearbox. Make sure that the
housing is positioned so that the smaller pin slides into the smaller bushing on the gearbox and the
larger pin slides into the larger bushing. The long housing studs will help to align the pump housing
in the proper position.
b) Secure the pump housing with the hex head housing bolts and tighten with the appropriate wrench.
On the FKL 25 use six 18mm long bushings over the six housing studs and install the cover nuts to
hold the housing in place during assembly.
c) Install the new rotor o-rings into the groove on the back of the rotor hub.
d) Now slide the rotor with one dot on the drive shaft and the rotor with two dots on the idle shaft.
Note: when sliding the rotor onto the shaft, the o-ring should be facing the pump housing.
←Double seal only
Figure 17

Fristam Pumps
16
e) Align the rotors with the pump shaft so that the large spline teeth on the rotor slide into the missing
teeth on the pump shaft.
f) Place the new rotor cap o-rings into the groove on the rotor caps.
g) Install the rotor caps over the rotor. Rotate the rotor cap so that the hole in the rotor cap lines up
with the threaded hole in the pump shaft.
h) Install the new rotor bolt o-rings into the groove in the rotor bolt.
i) Now thread the rotor bolt through the rotor cap into the pump shaft.
j) To tighten the rotor bolt, place the wooden dowel between the rotors as shown in Figure 18. Tighten
the first rotor bolt with the appropriate wrench to the torque specified in Table A2, page 5.
k) Tighten the second rotor bolt, place the wooden dowel between the rotors as shown in Figure 19.
Tighten the second rotor bolt clockwise with the appropriate wrench to the torque specified in Table
A2, page 5.
VERIFy ROTOR CLEARANCES
With the rotors installed, you should check the clearances around the rotor to ensure that the pump
was assembled properly. Use feeler gauges to verify the back and radial clearance between the rotors
and the housing. Use a depth micrometer to verify the front face clearance (see Table A3, page 6). If the
gap is incorrect, please see Setting the Rotor Gap section on page 19 (for the FKL 25, 75,150, 250 &
400 Series) or page 29 (for FKL 50). Rotate
the input shaft to verify that the pump turns
freely. If the gap is correct and the pump
turns freely continue Pump Assembly (below).
a) Install the pump cover o-ring onto the
pump cover.
b) Install the pump cover. Make sure the
threaded end of the forcing screws are flush
with the inside face of the pump cover.
For Jacketed Cover - install the jacketed
cover, replace the jacketed cover o-ring and
then continue with instructions below.
c) Secure the pump cover with the cover nut
washers and cover nuts. Tighten with the
appropriate wrench to the torque specified
in Table A2, page 5.
IL-0523
Figure 18
IL-0525
Figure 19

FKL Series Pump
17
d) Replace all shaft guards.
e) Reconnect the inlet and outlet piping.
f) Install the seal flush piping as shown in Figure 20.
g) Replace the seal flush supply and return lines to your pump if the pump is equipped with a double
mechanical or double o-ring product seal.
h) Verify that all valves on the suction and discharge side of the pump are open. You are now ready to
start the pump.
bEARINg AND/OR ShAFT REPLACEMENT
FOR ThE FKL 25, 75, 150, 250 & 400 SERIES
CAUTION! Begin all pump
maintenance by discon-
necting the energy source
to the pump. Observe all
lock out/tag out proce-
dures as outlined by ANSI
Z244.1-1982 and OSHA
1910.147 to prevent acci-
dental start-up and injury.
For Bearing and/or Shaft
Replacement for the FKL
50 Series see page 24-29.
TOOLS REqUIRED FOR
gEARbOx DISASSEMbLy:
Arbor press
3/8” Allen wrench
Screwdriver (small flat
blade)
1” diameter wooden dowel
Soft-faced hammer
Hammer (standard steel)
Brass rod
Bearing heater
Shim stock packet (order from Fristam prior to disassembly)
Torque wrench
Figure 20

Fristam Pumps
18
INDICATINg TORqUE WRENCh TOOLS REqUIRED FOR SPECIFIC PUMP MODEL:
FKL 25 FKL 75, 150 & 250 FKL 400
Gearbox cover bolts 13 mm wrench 17 mm wrench
17 mm wrench
Bearing cap screws 5 mm Allen wrench 6 mm Allen wrench
8 mm Allen wrench
SPANNER WRENCh REqUIRED FOR ThE bEARINg LOCK NUT FOR SPECIFIC PUMP MODEL:
FKL 25 FKL 75 FKL 150 FKL 250 FKL 400
M35 M50 M55 M75 M85
gEARbOx DISASSEMbLy
To start the gearbox disassembly, complete the Pump Head Disassembly on pages 11-12.
a) Remove the oil drain plug with the 3/8” Allen wrench and drain the oil.
b) Use the appropriate wrench to remove the gearbox cover bolts. Then remove the gearbox cover and
gearbox cover gasket.
c) Loosen and remove the bearing cap screws with the appropriate Allen wrench.
d) Remove the bearing caps.
e) Remove the bearing cap o-rings from both bearing caps and the rear oil seal from the drive shaft
bearing cap.
f) Install the rotors onto the pump shafts. Secure the rotors from turning by placing the wooden dowel
between them as shown in Figure 21.
g) Straighten the bent tab on the bearing lock nut washer on both the drive and idle pump shafts with
the screwdriver.
h) Loosen the bearing lock nut from both shafts using the spanner wrench.
i) Remove the bearing lock nuts, bearing lock nut washers and rotors from both pump shafts.
j) Place the gearbox on an arbor press with the spline ends of the shafts facing down as shown in Figure
22. Press on the shafts, one at a time, to remove them from the gearbox. Make sure to support the
shafts so that they do not fall and get damaged. Also, be sure to remove the rear bearing inner race,
rear gear spacer and the gear before pressing the other shaft. Press the inner bearing races off both
pump shafts. Note: do not press on the outer bearing cage. Set the pump shafts aside.
k) Remove the gears from the gearbox. The outer races of both front and rear bearings can now be
tapped out of the gearbox with a hammer and brass rod. Note that the front outer races may have
stayed on the shafts.
You are now ready to reassemble the gearbox.
gEARbOx ASSEMbLy
Note: The front and rear bearing
assemblies are matched sets. Do not
separate pieces.
Also,for ease of installation,install
the idle shaft first. If you are not
sure about shaft location, the drive
shaft will always be located in the
same bore on the gearbox. To locate
the correct bore, stand facing the
pump end of the gearbox with the
gearbox cover on your left side. The
drive shaft will be in the top bore
!
IL-0536
Figure 21

FKL Series Pump
19
position.
ASSEMbLE FRONT bEARINgS ONTO ShAFTS
Cover the coupling area of the drive shaft with
tape, to protect it. Lightly grease the front bear-
ing step on the pump shafts.
a) Press the front bearing cone on the shaft.
Use a hose clamp or tape to hold the cups
and outer spacer together (Figure 24).
b) Install the inner bearing spacer and outer
cup assembly over the bearing on the shaft.
c) Press the other bearing cone on the shaft.
d) Remove the hose clamp or tape
e) Install the front gear spacer on the shaft.
SETTINg ThE ROTOR gAP
Clean and inspect the gearbox.
a) Lightly coat the front and rear bearing bores
with oil. Note that before you install the outer
race for the front bearings, you must place the
shims in the bottom of the bore of the gear-
box as shown in Figure 25 and 26. For new
shafts, use 0.100” of shim and for used shafts
use 0.120” of shim.
b) Install the pump shafts into the correct bores.
Secure them in position using the front bearing caps, be sure to tighten the bearing cap screws to
the appropriate torque.
c) Carefully slide the pump housing over the pump shafts and onto the gearbox. Make sure that the
housing is positioned so that the small pin slides into the small bushing on the gearbox and the
large pin slides into the large bushing. The long housing studs will help to align the pump housing
in the proper position.
d) Secure the pump housing with the hex head housing bolts. Note: On the FKL 25 use six 18mm long
bushings over the six housing studs and install the cover nuts to hold the housing in place during
assembly. Tighten with the appropriate wrench.
e) Slide the rotors into the pump housing with the rotor o-ring groove toward the back of the pump
housing. It is not necessary to have the rotor o-rings installed at this time.
f) Align the rotors with the pump shaft
so that the missing spline teeth on the
rotor slides into the missing teeth on
the pump shaft.
g) Place the rotor caps over the rotor.
h) Rotate the rotor cap so that the hole in
the rotor cap lines up with the threaded
hole in the pump shaft and thread the
rotor bolt through the rotor cap into
the pump shaft.
i) Place the wooden dowel between the
rotors as shown in Figure 27.
j) Tighten the first rotor bolt with the ap-
SHAFT SUPPORTS
GEARBOX
ARBOR PRESS
IL-0578
Figure 22
1265000098 Rev A
GREASE
MUST BE CONCENTRIC
Figure 24