Grundfos Peerless Pump 8196 Series User manual

CUSTOMER __________________________
PO# _________________________________
SERVICE_____________________________
EQUIPMENT NUMBER__________________
SERIAL NUMBER______________________
Bulletin 4852840
Revised October 9. 2017
Peerless Pump Company
Series·8196
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
ANSI STANDARD PROCESS
PUMP

TABLE OF CONTENTS
Section I - General ............................................................................................................4
Introduction ..............................................................................................................................5
I-A. Importance of Instructions ...............................................................................................5
I-B. Special Warnings ..........................................................................................................5
I-C. Receiving Inspection-Shortages……………………………………………………..……5
I -D. Preservation and Storage …………………………………………………………..…….5
I-E.· Handling Techniques ………………………………………………………………..…...6
Section II – Installation ………………………………………………………………......7
II-A. Location…………………………………………………………………………………..7
II -B. Foundation…………………………………………………………………………. …...7
II-C. Foundation Bolts …………………………………………………………………………7
II-D. Mounting and Leveling the Unit ………………………………………………………7-8
II-E. Alignment ………………………………………………………………………………8-9
II-F. Alignment Check………………………………………………………………………9-10
II-G. Alignment Adjustment…………………………………………………………………..10
II-H. Alignment Recheck …………………………………………………………………10
II-I Grouting ...................................................................................................................10-11
II-J. Suction Piping-General………………………… ………………………………………12
Suction Lift Installations………………………………………………………………………………12
Flooded Suction! Positive Head Installations ……………………………………………………..12
II-K. Discharge Piping………..………………………………………………………………12
II- L. Engine Driven Units……………………………………………………………………13
II-M. Electric Motor Driven Units……………………………………………………………13
II-N. Installation Falk Steelflex® Spacer Couplings………………………………………14-15
II-O. Installation Wood's Sure-Flex® Spacer Couplings…………… ……………………16-17
II-P. Installation Rexnord Rex Omega® Spacer Type Couplings…………………………18-19
II-Q. Stuffing Box …………………………………………………………………………….20
Section III – Operation ………………………………………………………………….21
III-A. Start-up Check List…………………………………………………………….……21-23
Section IV - Preventive and Corrective Maintenance …………………………………24
IV-A. Daily/Weekly Routine Inspection and Maintenance……………………………………24
Section V – STP/MTP Power Frames ……………………………………………...…..25
V-A. Disassembly And Reassembly Instructions…………………………………..………...25
STP! MTP Pump Frames………………………………………………………………………25
Removal of Seal Chamber Cover……………………………………………………..……….25
Removal of Stuffing Box Cover-Packed Pumps………………………………………..………26
Page 2 4852840

Power End Disassembly-STP and MTP Models ............................................. ......26
Power End Disassembly-LTP Frames ............................................................ ......27
Power End Disassembly-XLTP Frames .......................................................... ......27
V-B. Parts Inspection …………………………………………………………………27-28
V-C. Assembly .......................................................................................................... ....29
Rotating Element and Bearing Frame, STP and MTP Frames ....................... ......29
Power End Assembly .................................................. .................................... ......29
V-D. Assembly ....................................................................: ........., ...................... ......30
Rotating Element and Frame Assembly, LTP and XLTP ................................ ......30
Rotating Element-LTP Frame ......................................................................... ......30
Rotating Element-XLTP Frame ....................................................................... ......31
Power Frame Checks and Liquid End Assembly - All Models ....................... ......31
Packed Type Pumps ................................................: .................................... ......32
Mechanical Seal Pumps .......................................... ..........................…………32-33
V-E. Installation-Back Pull Out Assembly - All Models .............................…………….34
Appendix ............................................................................................ .......................35
Oil Lubricated Bearings .............................................................. .......... ~ ..................... 35
Grease Lubricated Bearings .......................................................: ........ ......................... 36
Field Conversion from Flood Oil to Oil Mist Bearings ............... .........................37
Impeller Clearance Adjustment .................................................. .........................38
Feeler Gauge Adjustment of Impeller Clearance ........................ .........................38
. Dial Indicator Adjustment of Impeller Clearance ………...……… ………….39-40
Parts List with Materials" of Construction…………………………………………..…...41
Cross. Sectional Drawings
STP…………………………………………………………………………..……41
MTP………………………………………………………………………….……43
LTP………………………………………………………………………………..44
XLTP…………………………………………………………………..……...…..45
ANSI Process Pumps Engineering Data ………………………………………………46-47
Trouble-Shooting: Causes and Corrective Measures ……………………………..48
Ordering Spare Parts ………………………………………………….. ………….49
Instructions for Ordering Spare Parts ………………………………………….. 49
Modular Interchangeability Chart ……………………………………………….50
Exploded Isometric Views
STP…………………………………………………………………………..……51
MTP………………………………………………………………………….……52
LTP………………………………………………………………………………..53
XLTP…………………………………………………………………..…….. …..54
4852840 Page 3
SECTION I

GENERAL
READ THIS ENTIRE BOOK before attempting to install, operate or repair this pump. Properly in-
stalled, your pump will give you satisfactory, dependable service. We urge that you carefully read these
step
-by-step instructions, to eliminate any problems of installation, operation or repair.
Failure to read and comply with installation and operating instructions will void the responsibility of the manufacturer
and may also result in bodily injury as well as propert
y damage.
This book is intended to be a permanent part of your pump installation and should be preserved in a convenient location
for ready reference. If these instructions should become soiled, obtain a new copy from Peerless Pump Company
(
Include pump model and/or serial number with your request.
New equipment manufactured by Seller is warranted tobe free from defects in material and workmanship under
normal use and service for a period of one year from date of shipment; (Excluding Power Ends, which are
covered for three (3) years). Seller's obligation under this warranty being limited to repairing or replacing at its
option any part found to its satisfaction to be so defective provided that such part is, upon request, returned to
Seller's factory from which it was shipped, transportation prepaid. This warranty does not cover parts damaged
by decomposition from chemical action or wear caused by abrasive materials, nor does it cover damage
resulting from misuse, accident, neglect, or from improper operation, maintenance, installation, modification
or adjustment. This warranty does not cover parts repaired outside Seller's factory without prior written
approval. Seller makes no warranty as to starting equipment, electrical apparatus or other material not of its
manufacture, since the same are usually covered by warranties of the respective manufacturers thereof.
In the event, notwithstanding the terms of this agreement, it is determined by a court of competent jurisdiction
that an express warranty has been given by Seller to Purchaser with respect to the head, capacity or other like
performance characteristics of said equipment, Seller's liability for breach of the same shall be limited to
accepting return of such equipment EO.B. plant of manufacture, refunding any amount paid thereon by
Purchaser (less depreciation at the rate of 15% per year if Purchaser has used equipment for more than thirty
(30) days) and canceling any balance still owing on the equipment.
This warrantyis expressly in lieu of any other warranties, expressed or implied, and Seller specifically disclaims
any implied warranty of merchantability or fitness for a particular purpose
Page 4
4852840
WARRANTY

INTRODUCTION
This instruction manual is intended to assist those involved with the installation, operation and maintenance. of Peerless
Pump Company
ANSI Process Pumps. It is recommended that this manual be thoroughly reviewed prior to installing or
performing any work on the pump or motor.
I·A. IMPORTANCE OF INSTRUCTIONS
The design, material and workmanship incorporated in the construction of pumps by Peerless Pump Company
make
them capable of giving long, trouble-free service. The life and satisfactory service of an
y mechanical unit, however, is
enhanced and extended by periodic inspection and careful maintenance. This instruction manual was prepared to assist
operators in understanding the construction and correct methods of installing, operating, and maintaining th
ese pumps.
Thoroughly study Sections I, II, III and carefully follow the instruc
tions for installation. Sections IV and V have answers
to trouble and maintenance questions. Keep this instruc
tion manual handy for reference. Further information can be
obtained by contacting the local authorized distributor or the factory.
I·B. SPECIAL WARNINGS
Peerless Pump Company will not be liable for any damages or delay caused by failure to comply with the
provisions of this instruction manual. This pump is not to be operated at speeds, working pressures, discharge
pressures, or temperatures higher than, nor used with liquids other than, stated in the original order
acknowledgment without written permission of Peerless Pump Company. For Pressure/Temperature limitations
see page 46.
I-C. RECEIVING INSPECTION-SHORTAGES
Care should be taken when unloading pumps. If shipment is not delivered in good order and in accordance with the
Bill-of-Lading, note the damage or shortage on both receipt and freight bill.
MAKE ANY CLAIMS TO THE
TRANSPORTATION COMPANY PROMPTLY.
Instruction sheets on various components as well as the Instruction
Book for the pump are included in the shipment. DO NOT DISCARD!
I-D. PRESERVATION AND STORAGE
Peerless Pump Company normal domestic shipping and storage preparation is suitable for protect
ing the pump during
shipment in covered trucks. It also provides protection during covered storage at the job site, and for a short period
between installation and start-up. If the pump is t
o be idle and/or exposed to the elements for an extended period, either
before or after installation, special precautions are required. One ap
proach is to provide special preservatives and
wrapping before shipment. However, after installation the protect
ive wrappings will have been removed. Therefore,
application of preservatives after installation is considered a good practice. Information about various long term
preservation and storage options available can be obtained for the driver, coupling, mechani
cal seal, or other equipment
supplied on your order. Contact the factory for further details.
4852840
Page 5

I-E. HANDLING TECHNIQUES
Care should be used in moving pumps. Pumps should not be hoisted by eyebolts. These eyebolts are intended
for removing the back pullout assembly for maintenance and inspection. An assembled pump should be
hoisted using a sling under suction flange and under rear of bearing frame. Base plate mounted units shou
ld
be hoisted using slings under suction flange of pump, and frame of motor as shown below.
Page 6
4852840

SECTION II
INSTALLATION
II-A. LOCATION
Select a location for the pumping unit (pump, base plate, coupling and driver) which will:
(a)
Be clean, well ventilated, properly drained and provide accessibility for inspection and maintenance (see
outline drawing for dimension). Outdoor installation
s may require protection from the elements,
particularly freezing.
(b) The suction supply system must provide the pump with Net Positive Suction Head (NPSH) equal to or greater
than that required bythe pump at any capacityover the expected operating ran
ge. Ask your representative
for assistance if you do not understand how to calculate or measure suction supply system NPSH.
II-B. FOUNDATION
Concrete (reinforced as necessary or required) is most widely used for the foundation. In sufficient mass, it
pr
ovides rigid support, which minimizes deflection and vibration. It may be located on soil, structural steel or
building floors, provided the combined weight of the pumping unit and foundation does not exceed the al
lowable
bearing load of the support. Allo
wable bearing loads ofstructural steel and floorscan be obtained from engineering
handbooks; building codes of local communities give the recommended allowable bearing loads for different types
of soil.
II-C. FOUNDATION BOLTS
Before pouring the foundation, locate the foundation bolts using a template frame and provide anchor
age as shown
in Figure 1. See the outline drawings furnished with each pump for the exact location of the foundation bolts.
When pouring, allow for a grout thickness of % to 1-Yz
inches between top of foundation and bottom of base.
Roughen top surface to provide a good bond of the grout.
II-D. MOUNTING AND LEVELING THE UNIT
Use qualified personnel (riggers) to lift or move unit at any time. Never lift unit using hooks or slings on
shafts. Never place eyebolts in tapped holes except for removal of a part to perform service work.
When the unit is received with the pump and the driver mounted on the base plate, it should be placed on the
foundation and the coupling halves disconnected. The coupling should not be reconnected until the align
ment
operations have been completed. The base plate should be supported on rectangular metal blocks and shims or on
metal wedges having a small taper. The support p
ieces should be placed close to the foundation bolts (Figure 2).
On large units, small jacks made of cap screws and nuts are very convenient. In each case the supports should be
directly under the part of the base plate carrying the greatest weight and spa
ced closely enough to give uniform
support. A spacing of24 inches is suggested on medium size units. A gap of about 0.75 inches to 1.50
inches should
be allowed between the base plate and the foundation for grouting.
4852840
Page 7
CAUTION

Page 8
Adjust the metal supports or wedges until the shafts of the pump and driver are level. Check the coupling faces as well
as the suction and discharge flanges
of the pump for horizontal or vertical position by means of a level.
Correct the
positions, if necessary, by adjusting the supports or wedges under the base plate as re
quired.
Pumps and drivers mounted on a common base plate were accurately aligned before shipment. All base plates
are flexible to some extent and, therefore, must not be relied upon to maintain the factory alignment.
Figure 1. Foundation bolt location and anchorage
Realignment is necessary after the complete unit has been leveled on the foundation and again after the grout has set
and foundation bolts have been tightened. The alignment must be checked after the unit is piped and rechecked
periodically as outlined
in the followin
g paragraphs. To facilitate accurate field alignment, we do not dowel the pumps
or drivers on the base plates before shipment.
II-E. ALIGNMENT
Reliable, trouble free and efficient operation of a pumping unit requires correct alignment of pump and driver shafts.
Misalignment may be the cause of:
(a) Noisy pump operation
(b) Vibration
(c) Premature bearing failure (d)
Excessive coupling wear
Figure 2. Adjusting wedges for mounting
4852840
IMPORTANT

Page 9
Factors that may change the alignment of the pumping unit are: (a)
Settling of the foundation
(b) Springing of the base plate
(c) Piping strains
(d) Settling of the building
(e) Shift of pump or driver on the base
II·F. ALIGNMENT CHECK
The following
checking procedure applies to a pumping unit consisting of a pump, flexible coupling and driver
mounted on a common base plate. Check alignment as follows:
(a) Disconnect the coupling halves.
(b) Set the coupling flange gap to the dimension shown in ''Mounting Each Half Spacer" for Falk (page 151 Table
3 for Wood's (page 17) or refer to" Allowable Shaft Engagements" for Rexnord (page 18).
(c) The preferred test for parallel and angular alignment may be made with a dial indicator mounted as
Shown in Figure 3. Proceed as follows:
(1) Scribe the index lines on the coupling halves (as shown) or mark where the indicator point rests. (2) Set
indicator dial to zero.
(3) Slowly turn BOTH coupling halves so that index lines match, or indicator point is always on the mark.
(4) Observe dial reading to determine whether pump or driver needs adjustment.
(5) Acceptable parallel and angular alignment occurs when total indicator reading (complete turn)
does not exceed limits specified by the coupling manufacturer. Refer to pages 15 - 21. '
FIXTURE
Figure 3. Testing alignment, dial indicator
"(d) Test for parallel and angular alignment with a straight edge and feeler gauge as shown in manufacturer's instructions
in Section II-
N, 0, P. Wi~ coupling halves stationary, make trials at four places 90° apart. Perfect alignment
occurs when a straight
edge is level across the coupling halves and the same gauge just enters between the
halves, both conditions at all points,'
4852840

When significant operating temperature differential will exist between the pump and driver (i.e. steam turbine drive
with pump handling cold liquid), thermal growth will cause the hotter unit to rise. Compensate for this growth by
initially setting the hotter unit 0.003 inch to 0.005 inch low. When both units are at normal operating temperature, a
final che
ck of coupling alignment must be made. Correct the alignment if necessary.
Check for correct electric motor rotation as described in paragraphs (a) and (b) under paragraph IlM while
coupling halves are disconnected.
II-G. ALIGNMENT ADJUSTMENT
Since all base plates are flexible; they may be distorted from transportation or handling. Therefore, it may be necessary
to correct excessive parallel and angular misalignment by slightly shifting the leveling wedges under the base plate.
Tap lightly (in or ou
t) with a hammer. Recheck alignment after each shifting of a wedge.
(a) . In some instances, for factory aligned pumping units, it may be necessary to change the shims under the pump or
driver, or even relocate these factory-positioned units on the base p
late. Make such changes only after it is
certain that alignment cannot be obtained by shifting of the wedges.
(b) If wedges are shifted or shims changed a substantial amount to obtain proper alignment, recheck the piping
alignment and level of the shafts.
Pumping unit shafts must be level, have proper alignment and the piping must mate with the pump flanges
without strain. All three conditions must be correct to provide proper performance and long life of the pumping
unit
II-H. ALIGNMENT RECHECK
alignment, and correct as required, after:
(a) Mounting,
(b) The grout has hardened,
(c) Foundation bolts are tightened, (d)
Piping is connected,
(e) Pump, driver, or base plate is moved for any reason.
II-I. GROUTING
Unless otherwise specified on the unit outline drawing, the base plate must be filled with grout and the leveling
wedges grouted in place. The product warranty IS VOID if this instruction is not followed.
Page 10
4852840
NOTE
NOTE

When the alignment is correct, the foundation bolts should be tightened evenly, but not too firmly. The unit can then
be grouted to the foundation. Foundation bolts should not be fully tightened until the grout is hardened, usually about
48 hours after
pouring. Installation without grout completely filling the base plate is ac
ceptable only when
recommended by specific notation on the unit outline drawing.
Grouting that completely fills a base plate is also necessary for minimum vibration levels, since a very stiff base is
uneconomical and unnecessary except for portable units. Grout compensates for unevenness in the foundation and base
plate and distributes the weight of the unit uniformly over the foundation. It also pre
vents the unit from shifting af
ter
mounting and alignment. It is essential that the pumping unit be expertly grouted by use of non
-
shrinking grout. The
mix required varies with the type of unit to be grouted, location and amount of grout. The instructions included with
the non
-shrinking grout package will provide the re
quired information for the proper mix for individual applications.
Grout the unit as follows:
(a) Build a form of plywood or thick planking around the foundation to contain the grout. Support ad
equately to
prevent deformation.
(b) Soak the top of the concrete pad thoroughly with water before grouting. Remove all surface water before
pouring.
(c)
Pour the grout through the holes provided in the base plate or through open ends of steel channel base plates.
While pouring, tamp liberally to fill all cavities and prevent air pockets.
In pouring and tamping, the grout may trap air in some places. Drill small vent holes through the base surface.
(d) After the grout has thoroughly hardened, tighten the foundation bolts and connect the piping.
Be certain piping does not strain pump flanges.
(e) Check the alignment after the piping is connected and the foundation bolts are tightened. (f)
Connect the coupling halves.
(g) After the grout has. thoroughly dried, apply an oil base paint to the exposed edges of the grout to prevent air and
moisture from encountering the grout
It is very important to support and restrain both the suction and discharge pipes near the pump to avoid
application of the forces and moments to the pump casing. Failure to support the piping properly can cause
excessive pipe strainon the casingwhich can affect alignment, cause vibration, andpromote rapid wear of seals
and bearings. Damage caused by pipe strain will void the warranty.
4852840
Page 11
NOTE
NOTE

II-J. SUCTION PIPING-GENERAL
The suction piping, if not installed properly, is a potential source of faulty operation. To achieve best performance,
provide for the following:
(a)
Avoid using elbows close to the pump suction flange. A minimum of six pipe diameters of straight pipe should
always be located between the elbow and suction inlet. If elbows are used, they should be long radius type.
(b) Suction pipe should be a minimum one size larger than the suction flange. Suction pipe should termi
nate at 'the
suction flange of the pump through an "eccentric reducer". Never install suction piping that is smaller in
diameter than the pump suction flange.
(c) Suction throttling must never be attempted. This could cause cavitation and damage to the pump.
(d) If a strainer is installed in the suction piping, it must have a net free area of at least three (3) times the area of
the suction pipe. It should be checked and cleaned periodically. The openings in the screen must be .smaller
than the sphere size allowed for the impeller. Contact factory for maximum sphere size.
(e) When the source of supply is feeding more than one pump, separate suction lines are recommended.
, SUCTION LIFT INSTALLATIONS
(a) Suction lines, when operating under lift conditions must be kept absolutely free from air leaks.
(b) Suction piping should gradually slope upward toward the pump and all joints must be air tight.
(c) Available NPSH must be greater than the NPSH requirement of the pump.
(d) Piping should be cleaned mechanically and chemically, and flushed prior to installing the pump. Several
mechanical seal and seizure troubles are due to improperly cleaned systems,
(e) A means of priming the pump (i.e., foot valve), must be provided.
FLOODED SUCTION/POSITIVE HEAD INSTALLATIONS
(a) The suction line must include an isolation valve to permit closing off
the source of supply so that pump
inspection and maintenance can be performed.The valve should be installed a minimum of two pipe diameters
from the pump suction flange.
(b) Piping should be level or slope gradually in a downward direction from the source of supply to avoid air
pockets.
(c) Piping should never extend below the pump suction flange. The piping entrance at the source of supply
should always be one to two sizes larger than the pump suction flange.
(d) To prevent eddies and vortices, the suction-pipe must be adequately installed below the surface of the liquid.
A minimum of three times the pipe diameter is recommended.
II-K DISCHARGE PIPING
(a) Check and isolation valves should be installed in the dis
charge line. The check valve must be placed between
the pump and the isolation valve. This will protect the pump from reverse rotation and ex
cessive back pressure.
The isolation valve is used in priming, starting and when shutting down the pump. If increas
ers are used on
the discharge side to increase the size of discharge piping, they should be placed between the check valve and
pump. When expansion joints are used, they should be placed between the check valve and pump.
Page 12
4852840

II-L. ENGINE DRIVEN UNITS
Safe and efficient operation of a pumping unit driven by an engine, whether diesel, or gasoline requires the
installation to satisfy the following requirements:
(a) Be well ventilated to keep the ambient temperature as low as possible. Taking 600F as a datum point, every
100 F rise in temperature reduces the horsepower of the engine by approximately 1%.
(b) Provide ample air for proper combustion.
(c) Provide the engine with an efficient exhaust system so that the combustion gases discharge with a
minimum of back pressure.
(d) Provide for a fuel system of adequate capacity which meets the local codes. (e)
Provide ample accessibility to service engine.
(f) Provide correct rotation of the pump. Engine rotation is determined at the factory. No mange of engine
rotation can be made in the field.
It is recommended that the operator become familiar with the installation and service manual supplied by the engine
manufacturer.
II-M. ELECTRIC MOTOR DRIVEN UNITS
For electric motor drives, connect power supply to conform with national and local codes. Line voltage and wire
capacity must match the ratings stamped on the motor nameplate.
(a) Only when the coupling halves are disconnected, momentarily energize the motor to check that ro
tation is in
the same direction as the arrow on the pump,
(b) If motor is three phase type, reverse rotation (if required) by interchanging any two of the three power leads.
The rotation of most single phase motors is fixed by internal wiring and cannot be easily changed.
4852840
Page 13

2.
4852840
Page 14
II·N. INSTALLATION FALK STEELFLEX
®
SPACER COUPLINGS
PARTS IDENTIFICATION - All coupling parts have identifying part numbers as shown above. Parts are interchangeable between the 10 Series and 1000 series
spacer couplings. However, to utilize the higher 1000 series ratings, the l
000T -
Blue Grid, Spacer Hubs, Shaft Hubs and Hardware must be used. When ordering
parts, always SPECIFY SIZE and TYPE shown on
the COVER. Sizes 80 thru 140T10
covers have been manufactured with two and three ribs; 00 NOT mix these
cover halves.
LIMITED END FLOAT - When electric motors, generators, engines, compressors and other machines are fitted with sleeve or straight roller bearings, limited
axial end floa
t kits are recommended for protecting the bearings. Falk Steelflex couplings are easily modified to limit end float; refer to Manual 428-
820 for
instructions.
CAUTION: Remove the coupling cover, grid and gap disc before removing the Spacer T Hub(s) of limited end float couplings. Reassemble as
instructed on Page 2.
LUBE FITTINGS - Cover halves have 1/8 NPT lube holes. Use a standard grease gun and lube fitting as instructed in Step 8 on Page 2.
LUBRICATION
- Adequate lubrication is essential for proper operation of the coupling. Refer to Table 1 on Page 2 for the amount of lubricant re
quired. It is
recommended that the coupling be checked once a year and lubricant ad
ded if required. For extreme or unusual operating conditions,
check more frequently.
.
CAUTION:
Consult applicable local and national safety codes for proper guarding of rotating members. Observe all safety rules when installing or servicing
couplings.
LUBRICATION SPECIFICATIONS
- Refer to Manual 428-010 for recommended lubricants. The foll
owing specifications applyto lubricants for Falk couplings
which are lubricated annually and operate within ambient temperatures of
0· to l50o·F. (-18o· to +66o C.
). For temperatures beyond this range, consult the Factory.
Dropping Pint· 300oF. (149oC.) or higher.
Consistency" NLGI No.2 with worked penetration value in the range of 250 to 300.
Separation and Resistance" Low oil separation rate and high resistance to separation from centrifuging.
Liquid Constituent - To possess good lubrication properties ... equivalent to a high quality, well refined petroleum oil. Inactive"
Must not corrode steel or cause swelling or deterioration of synthetic seals.
Clean - Free from foreign inclusions.
Semi-Permanent Lubrication" Refer to Manual 428-012 for details.
INSTALLATION
· Only standard mechanics tools, wrenches, a straight edge' and feeler gauges are required to Install Falk Steelflex couplings. Cou
plings Sizes
1020 thru 1090 are generally furnished for CLEARANCE FIT with set screws. Sizes 1100 and larger are furnished for an INTERFERENCE FIT without set screws.
Heat hubs with interference fit in
an oil bath to a maximum of 275o F. (135o C.) to mount. The oil flashpoint must be 275o·F. (135o C.)
or higher. Refer to Page 2 for
detailed mounting instructions.
REMOVAL AND INSTALLATION OF SPACER ASSEMBLY (SEE LIMITED END FLOAT "CAUTION")
REMOVE
SPACER ASSEMBLY - Remove pipe plugs and all but two fasteners opposite each other in each hub. Loosen these about one-quarter inch and tap
them with a mallet to disengage Steelflex Spacer from the shaft hubs. Remove fasteners and Spacer.
INSERT SPACER
ASSEMBLY- Do not allow them to protrude beyond flange face. Compress spacer to eliminate its gap, and insert into space between shaft
hubs. Carefully engage the hub registers and then alternately tighten fasteners. Torque to specifications in Step 2 on Pag
e 2.
INTRODUCTION
-This manual applies to Sizes 20 through 140T31 and 1020 thru 1140T35 Falk Stee1fIex Tapered Grid Spacer Couplings. Unless oth
erwise
stated, in
formation for Sizes 1020 thru 1140 applies to Sizes 20 through 140 respectively, e.g. 1020 = 20, 1100 = 100, etc. The type T
31 Steelflex Spacer Assembly
permits installation or removal (as shown in Steps A and B below) without disturbing either the driving or driven unit. These
couplings are designed to operate i
n
either the horizontal or vertical position without modification. However, for vertical applications, the match mark shown on Page 2, must be up. The performance
and life of the couplings depend largely upon how you install and service them. Carefully follow the instructions in this manual for optimum performance and
trouble free service.

INSTALLATION OF DISASSEMBLED TYPE T31 STEELFLEX
®
COUPLINGS
1. MOUNT SHAFT HUBS · Lockout starting switch of prime mover. Mount shaft hubs on their respective shafts so that hub face is flush
with the end of the shaft. If hub is furnished for an interference
fit, heat in an-Oil bath as instructed on Page 1. Position units for approxim
ate distance
between shaft ends with minimum angular and
offset misalignment.
2.
MOUNT EACH HALF SPACER - Stretch the seal and carefully roll it over hub teeth into position. Carefully position each half spacer on register of flanged
hubs and fasten parts together. Torque fasteners to value specified below left.
3. GAP AND ANGULAR ALIGNMENT - Use a spacer bar equal in thickness to the gap as specified. Insert bar, as shown above right, to same depth at 90- intervals
and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements must not exceed the ANGULAR limit
specified in
Table 1.
4. OFFSET ALIGNM
ENT - Align so that a straight edge rests squarely (or within the limits specified in Table 1) on both hubs and also at 90° interva
ls. Check with
feelers. The clearance must not exceed the OFFSET limit specified in Table 1. Tighten all foundation fasteners
and repeat Steps 3 and 4. Realign coupling if
necessary. NOTE: Use a dial indicator for more accurate alignment.
S. INSERT GRID - Pack gap and grooves with lubricant before inserting grid. When grids are furnished in two segments, install them so that all cut ends extend in
the same direction. This
will assure correct grid contact with the lug in the cover and permit cover installation. Spread the grid slightly to pass it-
over the coupling
teeth and then seat it with a soft mallet. Pack additional grease
between and around the grid and then wipe off the excess flush with top of grid.
6. COVER MATCH MARKS • Assemble the covers with the match marks on the same side. For vertical or inclined couplings, assemble the covers with the
match marks (and lugs) UP, or on the high side.
7. INSTALL COVER· Align seals with rover grooves. Position covers per Step 6 and insert gaskets at both joints. For Sizes 1020 thru 1070, position nut in hex
seats. insert all fasteners and torque to value Specified in Table 1. Insert pipe plugs.
8. LUBRICATION
- Lubricateannually. Refer toPage 1 for recommended lubricant specifications and toTable1 for amount oflubricant required.
Whenlubricating
remove both pipe plugs and insert a standard lubrication fitting in one hole. Whe
n grease flows from the vent hole, replace both plugs. Wipe off excess grease.
4842840 Page 15

II-O. INSTALLATION WOOD'S SURE-FLEX
®
SPACER COUPLINGS
Sure-Flex flanges (outer metallic parts) and sleeves (inner elastomeric members) come in many sizes and types. All rubber sleeves (EPDM) and Neoprene) have
the same ratings for a given size and may be used interchangeably. Hytrel sleeves, however, has completely different ratings.
Rubber sleeves must not be substituted
for Hy
trel... or Hytrel for rubber. First, determine the size and type of components being used. Remove all components from their b
oxes, and loosely assemble the
coupling on any convenient surface. (Do not attempt to install the wire
ring on the two-piece E or N sleeve at this time.)
1. Inspect all coupling components and remove any protective coatings or lubricants from bores, mating surfaces and fasteners. Remove any existing burrs, etc.
from the shaft
3.
Slide one coupling flange onto each shaft, using snug-fitting keys.
4.
Position the flanges on the shafts so that each shaft extends into each flange a minimum length equal to the shaft diameter.
Tighten one flange in its final position.
Slide the other far enough away to install the sleeve. With a two
-piece sleev
e, do not move the wire ring to its final position; allow it to hang loosely in the groove
adjacent to the teeth, as shown.
4. Slide the loose flange on the shaft until the sleeve is completely seated in the teeth of each flange. Tighten all fasteners to the values given in Table 2.
Different coupling sleeves require different degrees of alignment precision. Locate the earing failure (0) Excessive coupling wear
Page 16
4852840
Coupling size is marked on flanges.

SURE-FLEX" SPACER COUPLINGS, continued
5. Check parallel alignment by placing a straightedge across the two coupling flanges and. measuring the maximum offset at various points around the periphery
of the coupling. 00 NOT rotate the coupling. If the maxim
um offset exceeds the figure shown under "Parallel" in Table 3, realign the coupling.
6. Check angular alignment with a micrometer or caliper. Measure from the outside of one flange to the outside of the other at intervals around the periphery of the
cou
pling. Determine the maximum and minimum dimensions. DO NOT
rotate the coupling. The difference between the maximum and minimum must not exceed
the figure given under "Angular" in
Table 3. If a correction is necessary, be sure to recheck the parallel alignment. (Note:
For maximum life, keep misalignment values as near to zero as possible.)
NOTE: Periodically check elastomeric coupling sleeves for any visible evidence of deterioration. If deterioration is apparent, the coupling sleeve must be
replaced.
NOTE: Values shown above apply If the actual torque transmitted is more than 1/4 the coupling rating. For lesser torque. reduce
the above values by 112. "Type H sleeves (orange) should not be used as direct replacements for EPDM or Neoprene sleeves
(black) or with
J or B flanges.
7. If the coupling employs the two-piece sleeve with the wire ring. force the ring into its groove in the center of the sleeve. It may
be necessary to pry the ring into position with a blunt screwdriver.
8. Check safety codes and install protective guards or shields as required.
Reprinted with permission of T. B. Wood's Sons Co.
4852840·B
Page 17
(Dimension. are Inches)

II-P .
INSTALLATION REXNORD REX OMEGA SPACER TYPE COUPLINGS
WARNING
• Because of the possible danger to person(s) or property from accidents which may result from improper use or Installation of products, it
s extremely important to follow the proper installation and operational procedures
• All rotational power transmission products are potentially dangerous and can cause serious injury. They must
be properly
guarded and in compliance with OSHA standards for the speeds and applications in which they are used. It is the responsibility of the user
to provide proper guarding.
• Failure to secure cap screws property could cause coupling component(s) to become dislodged during operation; resulting in personal
injury. Do not start motor or job without the complete coupling being properly secured to driving and driv
en
equipment shafts.
• Before installing this coupling on any system containing sleeve bearings, herringbone gear sets or other devices sensitive to axial thrust,
consult Rexnord.
• It is the responsibility of the user to consider the coupling’s stiffness (available from Rexnord) as it relates to the drive system
frequency.
STEP 1: Inspect both driving and driven shafts and hub bores making sure they are free from dirt and burrs. Be sure the keys fit shafts properly. Mount both hubs
to the shafts securing only one hub; the other hub should be loose for minor adjustment of spacing. Where tapered bushings are used, follow bushing manufacturer's
instructi
ons. If hub is bored for an interference fit, we recommend heating the hub ~ water, oil bath" or an oven and quickly positioning it o
n the shaft. Do not spot
heat hub as it may cause distortion.
STEP 2: Place half of the elastomer element around hubs and secure with self-locking capscrews. The elastomer element will space the other hub. It is important to
have cap
screws properly tightened. See Table 1 below for recommended capscrew torques and instructions. Now secure the other hub to the shaft.
STEP 3: Mount other half of the elastomer element to hubs. Be sure to secure rings to the spacer element if provided. Tighten all cepscrews to the
recommended cap
screw torques in Table 1 and your done! .
HELPFUL HINT:
]f the cap screw holes in the element do not line up properly with the hubs due to equipment misalignment, rotate the shafts (if
possible)
slightly as you install each cap
screw. On larger coupling sizes, first install the cap screws that are located in the center of the half element.
ALLOWABLE SHAFT ENGAGEMENTS
Shafts can be flush with the hub (not shown), recessed below the face of the hub, or extended beyond the hub face.
Dimension Y should be equal to, or
greater than •. 8 times dimension X.
The shaft may extend beyond the htA>. as long as
there is sufficient keyway length available.
TABLE 1
Page 18
4852840

EQUIPMENT ALIGNMENT
Although Omega couplings can withstand gross misalignment, care should be taken for best possible alignment to assure optimum performance. The
caliper/straightedge alignment procedure is described below. If greater alignment accuracy is desired, a dial indicator method is recommended. There are occasions
when equipment manufacturers requi
re more specific alignment tolerances, in which case, the manufacturer's recommendations should be followed.
1. To correct for angular misalignment, use calipers to check the gap between hubs. Adjust or shim equipment until the gap is the same at all points around the
hubs.
2. To correct parallel offset, place a straightedge across the huh flanges in two places at 90" to each other. Adjust or shim equipment until the straightedge lays
flat on both sides.
3. Tighten down connected equipment and recheck a
lignment.
4. Install elastomer element, tightening all cap screws to the values shown in Table 1 as described on the reverse side.
5. If practical, recheck and tighten cap screws after several hours of operation.
ADJUST FOR ANGULAR MISALIGNMENT
ADJUST FOR PARALLEL OFFSET
4852840
Page 19

II-Q. STUFFING BOX
1.
Packing: Stuffing box packing is installed at the factory. Gland bolt nuts should be installed finger tight only.
Packing cannot run dry; it must be lubricated. If the pumped liquid
is clean, cool fluid, it may be used through
a bypass off the discharge to the lantern ring connection to lubricate the packing. If the pumped liquid
is dirty
or hot, it is not suitable to lubricate the packing. An external source must be uti
lized, unless the bypass is
equipped with proper separator, filter, and/ or cooling system. This must also be piped into the lantern ring
connection (refer to packing recommendations).
2. Mechanical Seals: When mechanical seals are supplied, they are installed and adjusted at the fac
tory. They
must not run dry or encounter abrasives in the pumped liquid. Connect recircula
tion, flush, and/ or cooling
lines as required, following instructions on the seal drawing supplied. On the
cartridge type seals installed at
the factory, the centering clips are removed. Follow instructions
on the seal drawing supplied. .
PACKING RECOMMENDATIONS
1. General Service Packing·- This is an Aramid-PTFE synthetic packing. It is best suited for cold water
and general service applications. It has a PH range of 0 to 12 and a maximum operating temperature of
500 degrees F. This packing is like Crane type 1345 or equal.
2. Chemical and Solvent Packing - This is a PTFE-Synthetic packing. It is used for severe chemical and
solvent applications. It has a PH range of 0 to 14 and a maximum operating tempera ture of 500 degrees
F. This packing is like Crane type C1065 or equal.
3. High Pressure and Temperature Packing - Often called Graphoil, it is used in high pressure and
temperature applications. It has a PH range of 0 to 14 and a maximum operating tempera ture of 750
degrees F.
PACKING SIZE
The following is a list of the standard packing size for all process pump models.
Frame
Packing
Approx.
No. of
Lantern
Size Size Length Rings Ring Width
.
STP 5/16 x 5/16 4.75 5 7/16
MTP 3/8 x 3/8 5.75 5 5/8
LTP 3/8 x 318 7.0 5 5/8
XLTP 7/16 x 7/16 8.0 5 5/8
Page 20
4852840