Torishima Pump CAL User manual

PT. TORISHIMA GUNA INDONESIA
CAL
END SUCTION

CAL Standard Design
SAFETY PRECAUTIONS
Before using this machine, be sure to read this “SAFTY PRECAUTIONS” and the
appended “INSTRUCTION MANUAL” carefully for proper operation.
After reading through this paper, be sure to keep it in the place exposed to view at all time
for operators.
Concerning the safety precautions, this paper describes the contents of WARNING by the use
of the following symbols and signs.
Indicating the contents where a possibility of leading to serious results such as
danger of injuries which persons may undergo in cases of mishandling due to
neglect of this display is conceivable.
Besides the above, the following WARNING label is affixed to the safety cover (coupling guard) of body coupling unit
or its vicinity.
The contents given below should always be following since any of them covers important note
on safety.
WARNING
1. General
1) Never allow any persons other than service engineers to engage in disassembly or repair, or remodeling work.
2) Never work alone and be sure to put on helmet, safety goggles, ear plugs, safety shoes, etc. in conformity with the
Labor Safety and Health Law, etc.
3) Prior to carrying out any sparking work such as welding, etc., make sure that there are no dangers of fire and
explosion hazards.
4) Check the place where emission of toxic gas and deficiency of oxygen are conceivable, such as pit, manhole, etc.
before starting on works and make sure of safety.
5) When carrying out the work for centering check, disassembly, etc., be sure to turn OFF the motor switch and affix a
tag indicating “NO POWER ON” or the like to the switch so that the switch will not be turned ON by mistake.
6) Before starting on work, be sure to conduct checking of singing outfits such as crane, wire-rope. etc. unfailingly.
7) Install safety fences around the working area and secure an emergency passageway.
8) Since any splits oil on the floor, passageway, etc. may lead to a cause of slippage etc., wipe it off forthwith.

CAL Standard Design
WARNING
9) Shaft seal parts will not function to stop the pumped liquid completely. When handling such a liquid which may
cause serious troubles to the human body, therefore, do not touch the splashing liquid from shaft seal parts.
10) Keep away from the casing of the pump that is handling such a hot liquid as may lead to a danger of scalds if
coming in contact with the human body.
11) Do not gain access to rotating parts recklessly since there is possibility of scattering caused by breakage of rotating
parts.
12) If you lean against, or step on the guard, it causes damage to the pump, and may result in scattering.
13) Do not open the terminal cover of electric equipment (motor, etc.) in live status. Otherwise, you may get electric
shock.
2. Handling
1) Where both pump and motor are assembled on the common bed, never hang a wire-rope on the eyebolt of the
motor. Furthermore, do not gain access to the underside of the suspended pump.
3. Direct-coupling
1) Fasten the coupling guard securely at the specified position with mounting bolts.
4. Maintenance
1) When carrying out the work for replacement of gland packing or mechanical seal, be sure to turn OFF the motor
switch and affix a tag indicating “NO POWER ON” or the like to the switch so that the switch will not be turned
ON by mistake.
5. Disassembly and Reassembly
1) Before carrying out the disassembly work, be sure to turn OFF the motor switch and affix a tag indicating “NO
POWER ON” or the like to the switch so that the switch will not be turned ON by mistake.
2) To drain liquid from inside of the pump, close the suction valve and the discharge valve completely. If the liquid is
at a high temperature, drain the liquid through the drain valve after the liquid cools down almost to a room
temperature.
3) When the pumped liquid is a chemical solution, it may cause injury (inflammation, etc.) if it touches the human
body. To prevent this, make sure that the liquid in the casing is completely drained.
4) When removing parts and partly-assembled components, hang wire-ropes to the positions as shown in the
Instruction Manual and use a chain block, etc.
5) When handling hot components such ball bearing, coupling, etc., be sure to put on protective gloves.

CAL Optional Design
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Instruction Manual
Contents
Contents.......................................................................................... 1
0. General .................................................................................. 1
0.1. Quality Control Plan .................................................... 1
0.2. Nameplate .................................................................... 1
0.3. Transportation .............................................................. 2
0.4. Construction................................................................. 2
1. Installation............................................................................. 4
1.1. Installation of base plate............................................... 4
1.2. Direct coupling............................................................. 5
1.3. Piping........................................................................... 5
2. Operation............................................................................... 6
2.1. Starting......................................................................... 6
2.2. Stopping ....................................................................... 7
2.3. Start/stop frequency ..................................................... 7
3. Maintenance Control ............................................................. 7
3.1. General......................................................................... 7
3.2. Shaft seal...................................................................... 7
3.3. Meters and gauge ......................................................... 8
3.4. Bearings ....................................................................... 8
3.5. Sliding Clearance ....................................................... 10
3.6. When the pump is left unused for a long period......... 10
4. Disassembling and Reassembling ........................................11
4.1. General........................................................................11
4.2. Disassembling ............................................................ 12
4.3. Reassembling ............................................................. 12
4.4. Spare parts.................................................................. 12
5. Mechanical seal................................................................... 13
5.1. General....................................................................... 13
5.2. Outline of Construction Parts..................................... 13
5.3. Causes leakage from mechanical seal ........................ 18
5.4. Disassembling ............................................................ 18
5.5. Inspection and maintenance of disassembled parts .... 19
5.6. Reassembling ............................................................. 19
6. Gland packing ..................................................................... 21
7. Troubleshooting................................................................... 22
7.1. Pump cannot be filled with liquid. ............................. 22
7.2. Pump cannot start....................................................... 22
7.3. Insufficient discharge or incapable of pumping ......... 22
7.4. Motor overload........................................................... 22
0. General
Carefully read this Manual before operating the CAL pump.
Also, keep this Manual at an easily accessible place.
All the pump components are manufactured under the strict quality
control system to assure of their specific performance. However,
our compensation shall be out of application to trouble or damage
caused by the following.
(1) Operation of the pump under liquid quality, density and
temperature, and running conditions which are deviated
from those specified in the pump specifications.
(2) Pump damage which is caused by improper handling and
operation, incorrect installation, use of improper materials,
improper piping, etc. -- that is – by noncompliance with the
descriptive instruction given in this Manual
(3) Pump damages caused by natural disaster.
The long-term satisfactory running of any pump will be ensured by
proper installation, handling and operation.
When repair is required, it is recommended to repair the pump by
our skilled serviceman as far as possible or to return it to our
factory.
In this Manual, each part name is followed with parenthesized part
number, when deemed as necessary, to easily identify the
components and parts.
0.1. Quality Control Plan
All inspection and test for material, dimension, performance, etc.
are performed in the manufacturing process in accordance with
quality control plan (QCP) submitted to the purchaser when the
pump was ordered. Only pumps that have fully satisfied the
specified performance values upon inspection and test are allowed
for shipment.
0.2. Nameplate
Each pump is provided with nameplate.
When ordering spare parts or replacement parts, let us have the
following information stamped on the nameplate.
(1) Pump type & size, Product No.(expressed with AP******,
etc.), date of production, etc.
(2) Parts name, material and quantity included in the Sectional
Drawing and Spare Parts List.

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0.3. Transportation
When transporting the pump directly coupled to a motor, apply a
wire rope to the pump and motor, as illustrated in Fig 0.3-1. (Do
not apply absolutely a rope to the eye-bolt of the motor.)
Fig 0.3-1
0.4. Construction
The CAL pumps provide single-stage, axial single-suction structure
for vertical (upward) discharge. The pump casing is of back
pull-out type with integral-casted axial suction nozzle and top
discharge nozzle and support foot. The pump can be disassembled
and internally inspected without removing the casing (1020) from
the piping.
Refer to Table 0-1 for a representative Pump Sectional Drawing.
Table 0-1 Pump structure
Pump structure Reference
figure
Mechanical seal (type of CA)
Oil lubrication (round oil gauge) Fig 0.4-1
Gland packing
Grease lubrication Fig 0.4-2
Mechanical seal
Oil lubrication (constant level oiler) Fig 0.4-3
Note1. The above figure is one structural example.
Note2. In the case of a mechanical seal of the option type, refer to Fig 0.4-3 .
Fig 0.4-1 Sectional Drawing (mechanical seal type is “CA”, oil lubrication with round oil gauge)

CAL Optional Design
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Note 1. The above figure is one structural example.
Note 2. The structure of gland packing is different depending on use conditions, refer to Section 6 (P.21).
Fig 0.4-2 Sectional Drawing (gland packing, grease lubrication)
Note 1. The above figure is one structural example.
Note 2. The structure of mechanical seal is different depending on use conditions, refer to Section 5.2 (P.13)
Fig 0.4-3 Sectional Drawing (mechanical seal, oil lubrication with constant level oiler)

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0.4.1. Volute casing
Back pull out type volute casing (1020) is fixed with the casing
cover (1610) and bearing housing (3300) at the driver side by
means of bolts. The flat gasket (4000.3) is inserted between the
mating surface of the volute casing (1020) and the casing cover
(1610) to seal the pumped liquid.
The following models provide double volute casing structure to
reduce radial thrust.
125-400, 200-250, 150-315, 150-400
0.4.2. Impeller
The impeller (2300) is installed with balance hole to balance the
greater part of axial thrust. Sliding clearance between the casing
wearing ring (5020) and the impeller is held to the minimum so that
pumped liquid at discharge side will not return to suction side.
The impeller is inserted through the shaft (2100), and fixed to shaft
(2100) with Hard Lock Nut® (9233). These Hard Lock Nut®
consist of two pieces of bottom nut (convex type) and upper nut
(concave type), special nuts having looseness preventive function.
0.4.3. Shaft seal
Casing cover (1610) as a part of the shaft seal is jointed, together
with bearing housing (3300), to volute casing (1020).
The shaft seal is available in two types; the mechanical seal type
and the gland packing type.
(1) In the case of mechanical seal type.
For the shaft seal construction, refer to Section 5 (P.13).
(2) In the case of gland packing type.
For the shaft seal construction, refer to Section 6 (P.21).
0.4.4. Bearing
The pump shaft (2100) is supported with two ball bearings (3210).
The ball bearings are fit on the shaft, which are placed in the
bearing housing (3300).
0.4.5. Shaft
The shaft components of each pump type are interchangeable with
those of other pump. As shown in Table 0-2, the shaft is available
in six sizes, which cover all models of the CAL pumps.
Table 0-2 Combination of pump size and shaft size
[The case of 4 pole motor drive]
Shaft size Pump size
25-360 32-125 40-125 65-125
32-160 40-160 50-160 65-150
32-200 40-200 50-200 65-190
35-470 80-150
80-190 80-200 100-190
32-250 40-250 50-250 65-240
80-240 100-245 80-250
65-310 80-310 100-310
45-470 50-315
45-470A 150-200
125-250
80-400
55-530 200-250
125-315
100-400 125-400
65-530 150-315
150-400
[The case of 2 pole motor drive]
Shaft size Pump size
25-360 32-125 40-125 65-125
32-160 40-160 50-160
32-200 40-200 50-200
35-470 80-160
45-470 80-200
32-250 40-250 50-250 80-250
1. Installation
1.1. Installation of base plate
Perform installation and centering of the pump by skilled workers.
Incorrect installation and centering will cause various troubles
while the pump is in running.
When the pump and the motor are directly coupled on a common
base plate, the pump has been correctly centered before shipment.
However, when installing the base plate at a local site, follow the
sequence below and, after installation, check that it is leveled as
specified.
(1) Prepare packers and several kinds of 1mm to 0.1mm thick
shims for leveling adjustment use, prior to installing.
(2) After complete setting of the foundation concrete, position
each packer at both sides from each foundation bolt and at
the portions equivalent to both side from each of the pump
and motor support feet. After positioning, place a mortar
onto the foundation floor (under the base plate) in each
packer position and the place each packer on the motor. In

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this case, keeps each packer horizontal using a level. At this
step, each packer requires no height adjustment, because it
is adjusted in installing the base plate.
(3) After complete cure of the mortar at each packer, preinstall
the common base plate (which pump and motor) onto the
packers and then confirm the center height of the pump.
After that, adjust the axial and crosswise horizontality of
the pump by inserting leveling shims while reading a level,
which shall be held on the discharge flange surface of the
pump.
(4) After complete positioning and leveling of the pump,
perform pre-centering of the pump to the motor by use of
specific centering tool (See Subsection 1.2). At this time, it
is recommended to record the numerical centering data
because thy can be usefully referred to in checking the
centering accuracy in directly coupling the pump to the
motor.
(5) After completion cure of the pre-centering work, fill up
each anchor hole (foundation bolt hole) with concrete.
(6) After completion cure of the grouted concrete, tightly
tighten each foundation bolt with nut. In this case, adjust
and check the direct coupling accuracy between the pump
and motor, based on the recorded pre-centering data.
(7) Grout mortar under the common bed until it reaches
perfectly all the corners of the base plate, so as not to
permit a cavity to be formed under the base plate.
(8) After completion of all the above works, connect the
discharge pipe and suction pipe to the corresponding
connection flanges of the pump.
1.2. Direct coupling
The pump shaft and the motor shaft must be kept in line with one
another. So, follow the procedure below in centering and leveling
the coupling set.
(1) Be sure check the rotational direction of the motor prior to
direct coupling.
The correct rotational direction is indicated with an arrow
mark on the bearing housing (3300), clockwise (CW)
toward the pump as viewed from the motor side.
(2) To check the rotational direction of the motor with the
pump that uses a flanged flexible shaft joint, remove the
coupling bolts. With the pump that uses a rubber shaft joint,
slide the couplings to the pump side and the motor side
each, and tighten the set bolt on the motor side. You must
check the rotational direction when the motor is not in
direct connection with the pump.
Checking the rotational direction of the motor in direct
connection with the pump causes a fault of the mechanical seal.
(3) After checking the rotational direction, directly connect the
motor and pump couplings.
(4) For centering work, put a straight-edge on the periphery of
both couplings, put a wedged-edge on both surfaces of the
couplings, and use calipers, etc., as shown Fig 1.2-1. To
conduct the centering work more easily and accurately, you
should use a dial gauge.
(5) In this step, verify coaxiality and parallelism at four points
at 90°angles, to verify that the measured values do not
exceed those listed in Table 1-1.
Table 1-1
Shaft joint Coaxiality
A (mm)
Parallelism
B1 −B2(mm)
Flanged flexible shaft joint 0.05 0.05
Rubber shaft joint 0.5 0.5
Fig 1.2-1
(6) Be sure to tighten the set bolt completely.
(7) If the pumped liquid is not at a room temperature, re-check
the centering condition after the pumped liquid is stabilized
at the specified temperature.
1.3. Piping
For piping work, follow the instructions given below.
(1) During connections of the suction pipe and the discharge
pipe, be careful not to apply force from the pump to each
pipe. If force is applied from the piping to the pump, the
pump may abnormally vibrate, causing a failure of the
pump.
(2) In piping design, minimize various piping losses in the
suction line. For the purpose, avoid acute change of pipe
section and acute bending of pipe and select such a pipe
size as can ensure flow velocity of 3m/s max.
(3) To prevent an air pocket in the suction pipe, kept it in
upward slope toward the pump, in the case of pumping up.
(4) If a suction pipe diameter is different from the pump
suction port diameter, connect an eccentric taper tube as
Straight-edge
Calipers
Wedged-edge

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shown in (Fig 1.3-1), so that an air pocket is not present.
Fig 1.3-1
(5) When connecting a valve to the discharge line, locate it as
close as possible to the discharge nozzle of the pump. To
provide a check valve, connect it between the pump
discharge port and the discharge valve.
(6) Where no flushing is applied to pipeline, foreign matter
existing in the pipeline flows into the pump while the pump
is in initial running. Therefore, the pump inlet must be
provided a strainer no shut out inflow of such a foreign
matter. A strainer used must have the effective area as large
as 3 to 4 times the sectional area of the suction. If the
strainer is clogged during pump running, the indicated
value on the suction line pressure gauge will fluctuate. In
such a case, the strainer must be disconnected for removal
of clogged matter. The strainer can be removed when it can
be confirmed that no foreign object remains in the piping.
(7) Small piping such as flushing, etc. are designed and
manufactured in alignment with the application and shape,
so that they can be easily connected to the pump. In this
case, too be careful no to apply abnormal piping load to the
pump components, similarly to the main piping.
Furthermore, prior to connecting, check internally each
small pipe for existence of residual foreign matter and, if
necessary, clean it for complete removal of residual foreign
matter.
(8) High temperature or temperature fluctuation of lifting
liquid, if any, will result in expansion or shrinkage of the
pipeline. When such a phenomenon is forecast, add a
flexible pipe, etc. to the midway of the pipeline to protect
the pump from thermal expansion load.
(9) After completion of all the piping connection, recheck the
pump to motor direct-coupled condition to confirm that it is
free from center-deviation caused by abnormal piping load.
2. Operation
2.1. Starting
When putting the pump in initial operation after the installation, be
sure to check the following items for normality, prior to starting. If
abnormality de found upon checking, take corrective actions in
accordance with the Troubleshooting Instructions given in this
Manual.
(1) The rotational direction of the motor… Is the correct? The
correct direction is clockwise (CW) in face to the pump at
the motor side. With the pump using the flanged flexible
shaft joint, remove the coupling bolt when you check the
rotational direction. With the pump using the rubber shaft
joint, make sure that inside of the pump is completely filled
with pumped liquid before turning ON the motor switch.
Immediately after turning ON the motor switch, turn it OFF,
and check the rotational direction of the motor.
(2) Verify that the pump shaft and the motor shaft are directly
connected in the specified centering condition. Verify that
the coupling bolt is mounted (when the flanged flexible
shaft joint is used), and that the set bolt is securely
tightened.
(3) Are small pipes connected perfectly? Is the flushing liquid
injected and drained as specified?
(4) In the case when a strainer is connected to the suction line,
is not it clogged with foreign matter?
(5) Is the suction line valve fully opened? Is the discharge line
valve fully closed?
(6) Are suction line and the pump internally full with pumped
liquid? Is air purged out of them? (No-load running of the
pump prohibited)
(7) Check for leakage or other abnormal condition when the
suction pipe and inside of the pump are filled with pumped
liquid.
(8) No leakage from the mechanical seal?
(9) Can the coupling set be smoothly turned by hand? When
you turn the coupling manually, be sure to turn OFF the
motor switch, and affix a tag indicating “DO NOT TURN
ON” or the like to the switch so that the switch will not be
turned ON by mistake.
After checking the above items and making sure that there is
nothing abnormal, turn on the motor start switch and turn it off
immediately. Confirm that the pump runs smoothly and stops
quietly.
If nothing abnormal be found, turn on the motor start switch and
slowly open the discharge valve until the discharge flow reaches

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the specified rate.
When it comes off from the rated flow remarkably and
it drives, it causes the following accidents, and do the
flowing quantity adjustment surely.
When flowing quantity is too small:
abnormal vibration, abnormal noise, pumped
liquid temperature abnormal rise
When flowing quantity is too large:
abnormal vibration, abnormal noise,
overloaded motor
Even when restarting after log-term shut-down of the pump, be
sure to check each of the above items for normality.
2.2. Stopping
For stopping the pump, follow the instructions given below.
(1) Fully close the discharge valve. Generally the pumps with
check valve do not need this operation. However, if water
hammer may occur when the pump suddenly stops, the
discharge valve must be fully closed.
(2) Switch off the motor. In this step, make sure that the pump
smoothly slows down to stop.
(3) If the pumped liquid may freeze up, completely drain the
pumped liquid from inside of the pump and the
water-cooled jacket.
2.3. Start/stop frequency
If start/stop operations are frequently repeated, it causes a fault of
the pump and the motor. Do not repeat start/stop operations more
than the specified frequency.
If start/stop operations may exceed the specified frequency, consult
us.
(1) 2P type: Up to once in 5 hours
(2) 4P type: Up to twice in one hour
3. Maintenance Control
3.1. General
While the pump is running, check the following items and, if
anything abnormal be found, stop the pump immediately, and
check the following items:
(1) Is the pump running free from abnormal noise and
vibration?
(2) Does the suction pressure meet the NPSH required for the
pump? (Read the suction line pressure gauge for checking.)
(3) Is the discharge pressure kept as specified?
(4) Is the motor free from overload?
(5) Is the pump casing full with lifted liquid during the pump
running? And is the discharge valve kept closed?
(6) Is each bearing free from abnormal temperature rise?
3.2. Shaft seal
3.2.1. In the case of mechanical seal type
It is one outstanding feature of mechanical seal that requires almost
no maintenance while the pump is in running. However, the sliding
surface of seat (4750) and washer (4720) may eventually wear after
long-term running. Of course, the degree of this wear depends on
various factors such as running conditions, lubricity of pumped
liquid, existence of impurities in pumped liquid, etc. It is
impossible to define a replacement interval for wearable parts (seat,
washer). Therefore, it is recommended to store the running data,
which can be utilized to know the approximate replacement
interval of such wearable parts. Furthermore, it is recommended to
always stock spare parts for the mechanical seal and to replace all
when replacement is required.
In the case of the pump with mechanical seal, do not operate it in
dry condition and be sure to carry out priming before starting and
start the pump, with the stuffing box filled up with liquid. For
further take note, occasionally liquid may leak a little from the
mechanical seal, after started, until the seal becomes stable. This is
not abnormal.
Refer to Section 5 (P.13) for the detail of the mechanical seal.
3.2.2. In the case of gland packing type
The surface of gland packing (4610) and that of the shaft that slides
over it must be smooth at all times. If the shaft is scratched on the
surface, or gland (4520) is tightened unevenly or over-tightened, it
will cause the shaft seal to overheat or cause the gland packing to
wear quickly. When replacing gland packing, use a new one in a
material that will withstand the type of pumping liquid, and insert it
into casing cover (1610) so that its mating faces are shifted by 90
degrees to each other. For the gland packing, ring-shaped molded
packing is recommended.
If string-shaped gland packing is to be cut, use a tool such as the
one shown in Fig 3.2-1 when cutting.
Fig 3.2-1

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The gland should be slightly recessed from the casing cover. The
gland packing should be lightly tightened at the beginning. Then,
re-tighten it after running the pump for a certain period. Adjust the
gland packing so that liquid leakage from the gland is approx. 10 to
20 cc/min.
The dimension of the shaft seal and gland packing are shown in Fig
3.2-2 and Table 3-1.
Fig 3.2-2
Table 3-1 the dimension of the shaft seal and gland packing
Unit: mm
Shaft size
Shaft seal dimensions
Quantity of gland packing Gland packing dimensions Lantern
ring
dimensions
Lantern ring Molded part String-shaped part
D1 D2 D3 D4 Provided None D1×D2×B1 Thickness Overall
length (a) B2
25-360 24 40 53 9 4 6 24×40× 8 8 100.5 16
35-470
45-470 32 48 53 9 4 6 32×48× 8 8 125.7 16
45-470A
55-530 45 65 65 12 4 6 45×65×10 10 172.8 20
65-530 55 75 65 12 4 6 55×75×10 10 204.2 20
Use molded ring-shaped gland packing as much as possible.
3.3. Meters and gauge
It is recommended that a pressure gauge or compound pressure
gauge should be mounted to the pump body or the suction piping in
proximity to the pump, and that a pressure gauge should be
mounted to the discharge piping. These pressure gauges must be
provided with gradations capable of covering about 150% of
maximum operating pressure. Also connect a gauge cock to each
gauge. When pumping a corrosive liquid, use an anti-corrosion
gauge cock. When pumping liquid contains free matter or solid
matter, use a proper strainer with the gauge cock. For the long life
of each gauge, keep the gauge cock closed all the times, expect
when it is opened to read the operating pressure.
3.4. Bearings
Maintenance and inspection of the pump bearings are very
important. Maintenance and control of bearings of each lubrication
type are described below.
3.4.1. In the case of grease lubricated bearings
Inspection and control of the bearing temperature and replacement
of the ball bearings (3210) are required at an appropriate timing.
Heat-resistant grease is sealed in the bearing. The
maximum permissible temperature thereof is 90
degrees C max on the bearing housing (3300) surface
or ambient temperature plus 55 degrees C max.
The bearing replacement intervals vary depending on operating
conditions. During continuous operation, the bearings must be
replaced at an interval of approx. 9000 hours, as standard. In the
case of short-time operation, it is recommended that the bearings
should be replaced every two years. Further, it is recommended to

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replace the bearing together with shaft (2100) as shaft set (2101),
for easy replacement. Ball bearing type used is “Non-contact
double rubber seal type deep groove ball bearing (Clearance C3) as
shown in Table 3-2.
Table 3-2
Shaft size Ball bearing (JIS B1521 Designation No.)
25-360 6305 UUC3
35-470 6307 UUC3
45-470
45-470A 6309 UUC3
55-530 6311 UUC3
65-530 6313 UUC3
(Note)
1. Sealing grease shall be heat resisting grease.
2. Do not use the JIS designation Nos. given in Table 3-2 for
arrangements.
3.4.2. In the case of oil lubricated bearings
Inspection and control of bearing temperature and lubricating oils
as well as timely ball bearings (3210) replacement are necessary.
The maximum permissible temperature of each bearing
is 75 degrees C max on the bearing housing (3300)
surface or ambient temperature plus 40 degrees C max.
Before starting the pump operation, be sure to check the lubricating
oil level with the oil gauge (6430). To use the constant level oiler
(6380), check if lubricating oil is filled in the constant level oiler up
to one third or higher level.
When resuming the operation of the pump that has been stopped
for an extended period of time, clean the bearings and the inside of
bearing housing with cleaning oil. At this time, cleaning while
turning shaft (2100) by hand will remove dirt well.
When a new bearing is used, replace all amount of lubricating oil
after operation for the initial 300 hours. After that, the replacement
interval should be 3,000 hours of operation. The type of oil and
quantity are shown in Table 3-3.
The bearing replacement intervals vary depending on operating
conditions. During continuous operation, the bearings must be
replaced at an interval of approx. 9000 hours, as standard. In the
case of short-time operation, it is recommended that the bearings
should be replaced every two years. The ball bearing type used is
“Open type deep groove ball bearing (Clearance C3)”. The bearing
type codes in use are listed in Table 3-3.
Table 3-3 Oil lubricated bearings, and lubricating oil
Shaft
size
Bearing
JIS B1521
Lub. Oil
quantity
(liter)
Lub. Oil name
Below
1800min
-1
1800min
-1
or more
25-360 6305C3 0.25
VG46
Turbine
oil
VG32
Turbine
oil
35-470 6307C3 0.56
45-470
45-470A 6309C3 0.65
55-530 6311C3 1.08
65-530 6313C3 1.30
[In the case a round oil gauge is provided]
Check if the oil level is within the circle marked on the glass
surface of the round oil level gauge.
[In the case a constant level oiler is provided]
To replenish lubricating oil, remove the oiler cover (6386) together
with the Replenish (6382), and fill lubricating oil into the bearing
housing (3300) until it reaches the mounting (6383). Then, fill the
oiler with lubricating oil, and fit the oiler in mounting. Keep the oil
level in the constant level oiler at one third or higher level.
Fig 3.4-1

CAL Optional Design
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3.5. Sliding Clearance
Regarding the clearance between the case wearing ring and the
impeller sliding surface, the design value for the impeller whose
material is FC is φ0.4 mm, and the tolerance value is φ1.0 mm. The
design value for the impeller whose material is SCS is φ0.6 mm,
and the tolerance value is φ1.2 mm.
If the tolerance value is exceeded, replace the case wearing ring.
3.6. When the pump is left unused for a long
period
When the pump is left unused for a long period, execute break-in
operation for approx. 10 minutes once or twice a month. If break-in
operation cannot be performed, turn the shaft (2100) manually.

CAL Optional Design
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4. Disassembling and Reassembling
4.1. General
As its advantageous point, the CAL pump can be disassembled without demounting the volute casing (1020) from the base plate and the
pipelines. In disassembling, be careful not to impact and damages the Pump. Refer to the Pump Sectional Drawing submitted at the time of
order in disassembling and reassembling.
When rubber shaft joint is used When flanged flexible shaft joint is used
The above figure shows an example of pump and motor configuration. The type of configuration varies depending on the pump model and the motor being used.
Fig 4.1-1 Layout of Pump and Prime mover
The above figure shows an example of pump and motor configuration. The type of configuration varies depending on the pump model and the motor being used.
See the Pump Sectional Drawing submitted at the time of order.
Fig 4.1-2 Illustrated parts breakdown of pump

CAL Optional Design
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4.2. Disassembling
Follow the sequence below in disassembling
(1) Remove the coupling guard. When the flanged flexible
shaft joint is used, remove the coupling bolt.
(2) Remove the motor, and relocate it.
(3) Open the drain plug or drain valve located on the bottom of
volute casing (1020) to drain the pumped liquid out of the
casing, so that inside of the volute casing is open to the
atmosphere. For prevention of danger, be sure to check that
the liquid in the volute casing is completely cooled down,
prior to draining.
(4) Disconnect the small pipes from the pump.
(5) Remove the bolts (9010.C) for mounting the volute casing
and the casing cover (1610), nut (9200) for the stud bolt
(9020), and the bolts for fastening the support foot (1830)
to the bed.
(6) Remove bearing housing (3300) and casing cover together
with the rotor from volute casing by jack bolt (9010.B).
(7) For the oil lubricated type, remove the oil drain plug to
drain lubricating oil from the bearing housing.
(8) Unscrew the Hard Lock Nut® (9233) and remove the
impeller (2300), washer (5500) and the key (9400.2). As for
the Hard Lock Nut®, first unscrew upper nut (concave
type), and after removed it unscrew bottom nut (convex
type). Do not screw upper and bottom nut simultaneously.
(9) Disassembling the shaft seal.
For the mechanical seal type, refer to Section 5 (P.13).
For the gland type, remove the gland (4520) and remove
the lantern ring (4580) and the gland packing (4610).
(10) Separate the casing cover (1610) from the bearing housing
(3300). (It is convenient for reassembling to put a match
mark on both of the casing cover and the bearing housing.)
(11) For the grease lubricated type, remove the labyrinth (4230)
from the shaft. For the oil lubricated type, remove the drip
(5070) from the shaft.
(12) Unscrew the set bolt of the coupling and separate the pump
side coupling from the shaft with the coupling remover.
Check for wear and other damage of the element. If an
abnormal condition is found, replace the element with a
new one.
(13) Remove the both bearing covers (3600) from the bearing
housing.
(14) Slowly pull the shaft out of bearing housing, with the ball
bearings (3210) left in the bearing housing.
(15) When replacements of the ball bearings are required,
remove the rubber seal and heat up the ball bearings only
by acetylene gas, etc. And remove them from the shaft.
Caution: Do not heat the shaft.
(16) In principle, replace the flat gasket (4000) and O-ring
(4120) used for each seal surface with new ones when
disassembling the pump.
4.3. Reassembling
In reassembling, follow the reverse sequence of the disassembly,
with careful attention to the items given below.
(1) Wash each component / parts. Particularly do not permit
dust, etc. to adhere to the joint and contact portions.
(2) When ball bearings (3210) of the grease lubrication type
are used, press-fit the bearings on the shaft (2100). For the
oil lubricated type, heat up the ball bearings with oil at 110
to 120°C, and shrink-fit them on the shaft.
In this case, insert the bearings securely until they touch the
stepped parts of the shaft.
(3) Use caution not to damage the sealing surfaces and contact
surfaces of the flat gasket (4000), and other parts.
(4) As for the Hard Lock Nut® (9233), first fasten bottom nut
(convex type) fully, and then fasten upper nut (concave
type).
(5) After completion of the reassembling work, recheck the
direct-coupled condition pursuant to Subsection 1.2 (P.5)
and start the pump pursuant to Subsection 2.1 (P.6). When a
mechanical seal is used, slight leakage from the shaft seal
part may occur at the beginning of operation. However, the
leakage will be gradually eliminated. If leakage occurs even
after a considerable term of running, again disassemble the
pump for inspection.
4.4. Spare parts
4.4.1. Ordering spare parts
Send the following information, without fail, when ordering spare
parts.
• Pump size and pump type code
• Production No.
• Year of production
These are stamped on the nameplate affixed to the bearing housing
(3300).

CAL Optional Design
- 13-
4.4.2. Recommended spare parts
As shown in Table 4-1.
Table 4-1 Recommended Spare Parts and
Replacement Cycle
Item
No.
Parts
No. Parts name Replacement cycle (year)
1 2100 Shaft
*1
6 (9,000 hours or 2)
2 3210 Ball bearing
*1
9,000 hours or 2
3 4000 Flat gasket 2
*3
4 4120 O-ring 2
*3
5 4330 Mechanical seal 2
*3
6 4610 Gland packing 1
*3
7 5020 Casing wearing ring 6
8 5500 Washer (for Hard lock nut) 2
*3
9 9233 Hard lock nut 2
*3
*1 It is recommended to replace the bearings together with the
shaft for reduction of working manhour and improvement of
replacement work quality at customer side.
*2 Figure in parenthesis shows the replacement cycle in the case
of replacing the bearings together.
*3 When disassembling, replace them with new parts.
5. Mechanical seal
5.1. General
(1) The life of mechanical seal is remarkably shortened by
inclusion of foreign matter therein.
In reassembling the pump, clean the mechanical seal and
other internal components. In addition, be careful not to
permit such foreign matters to intrude in the pipeline during
running.
(2) Absolutely avoid dry running of the pump. (Including the
running under the seal box pressure below the atmospheric
bar.) Dry running will result in seizure trouble of the
mechanical seal, eventually causing not only the
mechanical seal but also the pump itself to be damaged.
(3) The sliding surfaces of the mechanical seal are fine finished
by lapping. Be careful to protect it from flawing and
chipping in handling.
(4) In principle, the sliding surface of the mechanical seal after
overhaul must be replaced with a new one, or must be
re-finished by lapping.
5.2. Outline of Construction Parts
For the mechanical seal sectional drawings, refer to Table 5-1.
The material of mechanical seal is different depending on use
conditions. Refer to the sectional drawing of pump.
Table 5-1 Mechanical Seal Type
Mechanical seal
type Remark Sectional drawing
CA φd SS
Rubber bellows type single
mono-coil seal
(simple type)
Fig 5.2-1
LCA φd F
LCA φd E
Rubber bellows type single
mono-coil seal
(clutch type)
Fig 5.2-2
LTW φd F
LTW φd E
Rubber bellows type double
mono-coil seal
(clutch type)
Fig 5.2-3
LA200-RFφd
LA200-REφd
LA200-RKφd
Multi-spring type single seal
(SiC ×carbon) Fig 5.2-4
L9SA-SEφd
L9SA-SKφd
Multi-spring type single seal
(SiC ×SiC) Fig 5.2-5
MBS100-RFφd Metal bellows type single
seal Fig 5.2-6
MBS100-RFφD is balanced seal. Other models are unbalanced
seal.

CAL Optional Design
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Note: For order of additional spare parts, designate the type of the mechanical seal as a set,
in order to ensure preferable seal effect.
Parts table of a mechanical seal set
Parts No. Parts Name
4100 Packing
4101 Cushion ring
4720 Sealing washer
4740.1,2 Follower ring
4750 Seat
4770 Spring
4850 Stopper
Mechanical seal type: CA φd SS
Unit: mm
Shaft size
25-360
35-470
45-470
45-470A
55-530
65-530 55
ｄ
24
32
45
Fig 5.2-1 Construction of mechanical seal “CA”
Note: For order of additional spare parts, designate the type of the mechanical seal as a set, in
order to ensure preferable seal effect.
Parts table of a mechanical seal set
Parts No. Parts Name
4100 Packing
4120.1 O-ring
4720 Sealing washer
4740 Follower ring
4750 Seat
4770 Spring
4850 Stopper
5061 Spline ring
9040 Set screw
Mechanical seal type: LCA φd F/E
Parts table of a pump
Parts No. Parts Name
5600 Pin
4120 O-ring
4710 Seal cover
Unit: mm
Shaft size
ｄ Ａ
25-360 24 37
35-470
45-470
45-470A
55-530
65-530 55 35
32
45
32
36.5
Fig 5.2-2 Construction of mechanical seal “LCA”

CAL Optional Design
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Note 1: For order of additional spare parts, designate the type of the mechanical seal as a set, in
order to ensure preferable seal effect.
Note 2: Quantity of flushing liquid and pressure of it are different depending on use conditions,
refer to pump-datasheet.
Parts table of a mechanical seal set
Parts No. Parts Name
4100.1,2 Packing
4120.1,2 O-ring
4720.1,2 Sealing washer
4740.1,2 Follower ring
4750.1,2 Seat
4770,1.2 Spring
4850 Stopper
5061.1,2 Spline ring
9040 Set screw
Mechanical seal type: LTW φd F/E
Parts table of a pump
Parts No. Parts Name
5600.1,2 Pin
4120 O-ring
4710 Seal cover
4751 Seat holder
Unit: mm
Shaft size
ｄ Ａ
25-360 24 44.5
35-470
45-470
45-470A
55-530
65-530 55 52.5
32
45
53
49.5
Fig 5.2-3 Construction of mechanical seal “LTW”
Conforming to DIN 24960 standard (Except for mechanical seal overall length)
Note: For order of additional spare parts, designate the type of the mechanical seal as a set, in
order to ensure preferable seal effect.
Parts table of a mechanical seal set
Parts No. Parts Name
4120.1,2 O-ring
4720 Sealing washer
4750 Seat
4770 Spring
4850 Stopper
9040 Set screw
Mechanical seal typ: LA200-RF/RE/RK φd
Parts table of a pump
Parts No. Parts Name
5600 Pin
4120.3 O-ring
4710 Seal cover
Unit: mm
Shaft size
ｄ Ａ
25-360 24 39
35-470
45-470
45-470A
55-530
65-530 55 41.5
32
45
41
43
Fig 5.2-4 Construction of mechanical seal “LA200” (SiC ×carbon)
4120.2

CAL Optional Design
- 16-
Conforming to DIN 24960 standard (Except for mechanical seal overall length)
Note: For order of additional spare parts, designate the type of the mechanical seal as a set, in
order to ensure preferable seal effect.
Parts table of a mechanical seal set
Parts No. Parts Name
4120.1,2 O-ring
4720 Sealing washer
4750 Seat
4770 Spring
4850 Stopper
9040 Set screw
Mechanical seal type: L9SA-SE/SK φd
Parts table of a pump
Parts No. Parts Name
5600 Pin
4120 O ring
4710 Seal cover
Unit: mm
Shaft size
ｄ Ａ
25-360 24 37
35-470
45-470
45-470A
55-530
65-530 55 39.5
32
45
39
40
Fig 5.2-5 Construction of mechanical seal “L9SA” (SiC ×SiC)
Conforming to DIN 24960 standard
Note: For order of additional spare parts, designate the type of the mechanical seal as a set, in
order to ensure preferable seal effect.
Parts table of a mechanical seal set
Parts No. Parts Name
4120.1, 2 O-ring
4720 Sealing washer
4750 Seat
4810 Bellows
4850 Stopper
9040 Set screw
Mechanical seal type: MBS100-RF φd
Parts table of a pump
Parts No. Parts Name
5600 Pin
4120 O-ring
4710 Seal cover
Unit: mm
Shaft size
ｄ Ａ
25-360 24 37
35-470
45-470
45-470A
55-530
65-530 55 38
32
45
36.5
40
Fig 5.2-6 Construction of mechanical seal “MBS100”

CAL Optional Design
- 17-
5.2.1. Quench
For the carbon bush type quench structure, refer to Fig 5.2-7. For
the oil carbon bush type quench structure, refer to Fig 5.2-8.
• Quench flow rate: 1.0 liter/min or less
• Quench pressure: 0.03 MPaG or less
Fig 5.2-7 Quench (Carbon bush type)
Fig 5.2-8 Quench (Oil seal type)
To execute quenching with the carbon bush type by using water, the
water flow rate and pressure should be as shown below. If it is
expected to exceed the following flow rate and pressure, use the oil
seal type.
• Quench water flow rate: 1.0 L/min or less
• Quench pressure: 0.03 MPaG or less
To execute quenching by using air, the quench pressure should be
the same as that for water quenching. The flow rate should be
appropriately determined.
The oil seal type should be used to execute quenching by using a
liquid with high lubrication property. The quench pressure should
be the same as that for the carbon bush type. The flow rate should
be appropriately determined.
• Quench pressure: 0.03 MPaG or less
5.2.2. Jacket water cooling
In case a jacket water cooling type, refer to Fig 5.2-9.
Do not use the liquid with a strong causticity for cooling water
because the material of the jacket cover (1650) is a cast iron. The
temperature and the pressure of cooling water should be assumed to
be the next.
• Temperature of cooling water: 30 ° C or less
(At inlet of cooling water)
• Pressure of cooling water: 0.3MPaG or less
The cooling water flow rate is different depending on use
conditions. Refer to the pump data sheet.
Fig 5.2-9 Jacket water cooling
5.2.3. External flushing
For the external flushing type, refer to Fig 5.2-10. To inject external
flushing liquid, the following two methods are available: The self
flushing method to flush pumped liquid over the seal cover from
the seat near the discharge flange, and the external flushing method
to flush liquid over the seal cover (4710) from an external source.
The models of mechanical seal that enable self/external flushing or
external flushing are LCA, LA200 and L9SA.
To flush liquid from an external source, the flushing flow rate
should be as follows:
• Flushing flow rate: 4 to 5 L/min.
The pressure of flushing flow is different depending on use
conditions. Refer to the pump data sheet.