Toyo DP 6 30-40HP Series User manual

TOYOPUMPS EUROPE Edition 27.07.2007
USERSMANUAL
Heavydutyslurrypumps

TOYOPUMPS EUROPE Edition 03.11.2009
SAFETYINSTRUCTIONS

TOYOPUMPS EUROPE Edition 03.11.2009
Usersmanual
forToyo pumps
type«DP..-630~40HP»
Thisusersmanualwillhelpyou to
maintainyourToyopumpinoptimum
working condition foralongtime.
Pleaseread carefullybeforeusing the
pumpand keep forfuturereference.
Takenoteof the serialnumberwhich
you can findon theidentification plate
of yourpump.
The manufacturerreservestherighttomodify
specificationsandconcept of theseproducts
without previousnotice.
Edition 27.04.2007
TOYO PUMPS EUROPE
ParcIndustrielSud –Zone II
Rue de l’Industrie, 41–1400Nivelles–Belgique
Tel.: [phone]
Fax. : [phone]
E-mail : [e-mail]
Website: www.toyopumpseurope.com

TOYOPUMPS EUROPE Edition 03.11.2009
CONTENTS
Introduction 1
Precautionsbeforeoperating 1
Noteson driving 2
Maintenanceandtroubleshooting 3
Pointstobe attentive4
Troubleshootinglist5
Disassembling procedures7
Assemblingprocedures9
Technicalspecifications11
Pumpperformancecurve 12
Dimensions 13
Sparepartslist 14
Exploded viewdrawings19

TOYOPUMPS EUROPE Edition 03.11.2009-1-
INTRODUCTION
Awrong utilisationandaninadequatemanipulationofthe pumpwill causeunsatisfactory
performancesand earlytroubles.Therefore,pleaseread thisinstructionmanualcarefully
beforeoperating.
PRECAUTIONSBEFOREOPERATING
1.Powersupply
Check the powersupplyvoltage andfrequency byreferring tothe identification plateon
the pump.
Operationofthepumpon adifferentpowervoltage fromthe specifiedvoltagewillcause
impossibilityof pumping up andmotorburning.
2. Grounding
Makesuretoconnectthepumpcorrectlytothe earth.The earth-cableisthe greenand
yellowcolouredone.
3. Rotationdirection
Astothe rotatingdirection,counterclockwiserotation viewing fromthe suctionintakeside
(lowerside ofthe pump)isthe correctwayofrotating.The rotation direction ismentioned
on the identification plateofthe pump.
Afterconnecting the pump,letitturnoutoftheliquidtobepumped foraninstant, inorder
tocheck the direction ofthe motorbyobserving the agitator.Attention,theagitatorcould
detachitself when turning inoppositedirection.
You onlyneedtoinverttwoofthe threealimentation wireswhenevertheelectricmotor
turnsinthewrong direction.
Rotation withoutbeingsubmerged foralongerperiodoftimecausesdamagestothe
seals.
The rotating direction of theagitatorcan be verifiedinstantaneously.
Neverdrivethe pumpinoppositedirection, asthiscausesearlydamagestothe pump.
4. Protectionofelectricmotor
Inanycase,itisnecessarytoprotectthepumpwithacorrectlycalibrated thermal
protectiontoavoidanyoverload and toinstallastart-stop switch.
Pumpsgoing up from15 HPand morewillhavetobe setup withareactorstarterbox.
The supplierofthe pumpcan adviseyouthe adequatematerial.

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5. Cabtyrecable
a)The useofacabtyrecablewhichhasan inferiorsection orasuperiorlengththen
recommended can makethe starting up ofthepumpimpossibleand provokedamages
tothe motor.
Concerning thecharacteristics ofthe cabletouse,pleaserefertothe technical
characteristics of thepump.
b)Toavoidtearingoutthecable,makesurethatthe lengthofthe alimentationcable
correspondstothe depthat whichthe pumpwillhavetowork.
Whenlengtheningthecable,whichisfixed tothe pumpwithasecond cable,you
shouldmakesurenot tosubmerge theirconnection.
6. Dischargehose
The diameterofthe discharge hosefixed tothe pumphastobe adapted tothe
diameterofthe hosenippleofthepump.Thedischargehosewillpreferablybe fixed
withhalf-circularcollars.
NOTES ONDRIVING
a)Foryoursafety,nevertouchthe agitatorwhenthe pumpisconnected,andneverpass
underneaththepumpwhileitissuspended.
b)When the pumpisinduty, it hastobe immersed untilthe levelindicated on the schema
representing the dimensionsofthe pump.
c)If possible,avoidusing the pumpinconditionsthatprovokean overload.
See inparticulartoimmersethe pumpprogressivelyuntilthe materialtopumpis
reached.
d)Inspectthe good working condition ofthe pumpbysecuring thatthe intensityofthe
currentdoesnot exceed the value indicated onthe identification plateof the pump.
e)Avoidsuspendingthepump(verticalmodels)insuchwaythat itmightget buriedatthe
bottom.
f)Oncethelevelofthepumped liquidbecomesinsufficient, noisy functioning and
abnormalweararegenerated. Inthiscase, add liquidorstop the pumpand wait forthe
liquidtorise.
g)Despitetheeffectofthe agitator,oversized materials,suchaspiecesofwood,etc.
havethe propensitytopresentthemselvesatthe entranceofthe pump.Thereforethe
pumphastobe equippedwithironbarspermitting objectsofthe samedimensionas
the holesof the strainer. Consult yoursupplier.

TOYOPUMPS EUROPE Edition 03.11.2009-3-
h)The densityofthe pumped liquidcan beverified byraising ordescending thepump.A
toheavy densitycan provokethe blockage ofthe discharge hoseand ofthe pumpand
makepumping impossible. Heavy densitieshavetobe avoided.
i)Useasufficientresistantchain,whichwillbeattached tothe lifting eyesprovided on
the pumpfortransporting orhandling thepump.The anglebetween the twopartsof
the chainmaynot overshoot 60degrees.
j)Neversuspend the pumpbyitsalimentationcable.
k)Rinsethe pumpand the dischargehosewithcleanwaterbeforeturning it off.
MAINTENANCEAND TROUBLESHOOTING
a)Measureperiodicallythe voltageofthe alimentationcurrenttoverifythatthe pump
works at the correct voltage.
b)The insulation resistanceofthe motorhastobe verified atleastonceamonth.If the
resistanceof the motorisinferiorto100MOhm, the winding of the electricmotorhasto
be dried and thetightness of the cableschecked, etc.
c)The oilcapacityinthe undercoverhastobeverified every500 hours. Therefore,place
the pumphorizontally(verticalpumps).If needed,addoilasspecifiedinthe tableof
technicalcharacteristics ofthe pump(normalorbiodegrading)through theopening
provided tothisend.
d)If the presenceofwaterinthe oilisestablished(whitishemulsion),orifthe oilcontains
solidparticles(mud,etc.),itmeansthatthe sealsaredefective.Theirreplacementis
then required.
e)The quantityofoilinthe undercoverofthe pumpisspecified inthe technical
specificationsofthe pump.
f)If the flowofthe pumpisdiminishing,the spacebetween the impellerdisc and the
impellerhastobe checked.The recommended spaceisindicatedinthe technical
specificationsofthe pump.

TOYOPUMPS EUROPE Edition 03.11.2009-4-
POINTSTO BE ATTENTIVE
a)The maximumliquidtemperatureforthestandardversionsis60 °C.
b)Avoidthatpumped materials(ex.mud,…)arestickedon the motorpartofthe pump.
Thiscan provokean abnormalheatingof themotor. Clean thepumpif thisoccurs.
c)If airoccursinthedischarge hose,ithappensthattheliquidcannotbepumped any
more.Inthatcase,verifyifthedischarge hoseisplacedashorizontalaspossible(ex.
avoidtolarge spacebetween the floaters).

TOYOPUMPS EUROPE Edition 03.11.2009-5-
TROUBLESHOOTING LIST
Thepumpisindutybutdoesn’tturnevenas theswitchisin“ON”position.
•Thepumpemitsnosound:
-Electricalimentationproblem:
àVerifyif the networkisundertension and/orthegeneratorworks properly.
-Defectiveconnection orbreakdownof one of the alimentation wires:
àVerifyall connectionsand check thestateof the wires.
-Alimentation throwone singlephase:
àVerifythe connectionsand fuses.
•Thepumpemitsasound :
-Aforeign bodyblocs theagitatororisjammedbetween impellerand impellerdisc :
àRemovetheforeign body.
-The impellerdisc isblocked against theimpeller:
àAdjustthe spacebetween thetwopartsasindicated inthe technical
characteristics.
-Abearing isbroken :
àReplacethe bearing.
-Wirebreakdowninone of the wiresinsidethe windingof thestator:
àConsult yoursupplier.
-The statorisburned:
àConsult yoursupplier.
Thepumpturnswhentheswitchisin“ON”positionbut…
•Thepumpemitsanabnormal sound:
-Aforeign bodyblocs theagitatororisjammedbetween impellerand impellerdisc :
àRemovetheforeign body.
-The impellerdisc isincontact withthe impeller:
àAdjustthe spacebetween thetwopartsasindicated inthe technical
characteristics.
-Defectivebearing :
àReplacethe bearing.

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•Theflowofthepumpistoweak:
-The pumpturnsinthe oppositedirection :
àInversetwoof thethree alimentation phases.
-The levelof the pumped liquidisinsufficient :
àAdd tothe level.
-Obstruction at theentranceofthe pumporat the discharge hose:
àVerifyand clean up.
-Airinthe discharge hose:
àPlacethe hoseashorizontalaspossible.
-Wearof theimpellerand the impellerdisc :
àAdjustthe spacebetween thetwopartsasindicated inthe technical
characteristics.
-The pumpprovided toworkin60 Hzisfurnished in50 Hz:
àConsult yoursupplier.
-Insufficient discharge pressure:
àConsult yoursupplier.
•Thethermal protection disconnects:
-The densityof thepumped liquidistoimportant :
àLowerthedensitybylifting the pumpand/orbydiluing the pumped materials.
-Important voltage drop :
àReplacethe alimentation cablebyacablewithcorrectsection and lengthas
indicated inthe technicalspecification of the pump.
-The impellerdisc isincontact withthe impeller:
àAdjustthe spacebetween thetwopartsasindicated inthe technical
characteristics.
-One of thephasesismissing :
àCompleteinspection outofthe liquidofthe electriccircuitgoing fromthe
sourceuntill the electricmotor.
-The pumpprovided toworkin50 Hzisfurnished in60 Hz:
àConsult yoursupplier.
-The electricmotorisburned:
àConsult yoursupplier.

TOYOPUMPS EUROPE Edition 03.11.2009-7-
DISASSEMBLING PROCEDURES
Chooseadryandcleanplacetodismantleand reassembleyourpumpand installabase
on whichyou can putthe pump.It isalsowisetoprepareafewsmall boxesinwhichyou
can put thesmall partsdismantledfromthe pump. Preparealsosomerags, oiland tools.
The numbersmentioned between parenthesisesinthe descriptioncorrespond totheparts
numbersinthe sparepartslist.
1.Disassemblingoftheelectriccable
a)Unscrewthe cap nuts(1C)en removethe leadcover(8).
b)Disconnectthe electriccable(7A)oftheterminalboard(99A)andremovethe packing
(2).
c)Incaseyou wanttodismantlethe motorcase(28),you need,atthisstage,alsoto
disconnect fromthe terminalboard(99A)the wirescoming out fromthe electricmotor.
d)If you wishtoreplacethe electriccable(7A), unscrewthe cap nuts(106C)and release
the packinggland (3)withthe cableprotectiontube (6), the packing set ring (5)andthe
packings(4).
2. Disassemblingofthepumpsection
a)Placethe pumphorizontallyandfixitinsuchwaythatitcannotmoveduringthe
disassembling procedure.
b)The cutterfan(81)isscrewed (normalrightthread)on theshaft(29).Todismantlethe
cutterfan,hititwithamalletorhammer,byinterposingabronzeoraluminiumjig,on
one ofthe cornersofthe cutterfan.Unscrewit incounterclockwisedirection,thepump
seen frombeneath(aspiration side).
c)Unscrewthe set bolts(79A)andremovethe strainer(80).
d)Unscrewthe cap nuts(69C)andremovethe suction cover(74)togetherwiththe
impellerdisc (73)withthe adjustbolts(69D).Removethe packing(77)andclean
carefullyitslocation inthevortexcasing.
e)Separatethe suction cover(74)fromthe impellerdisc (73)byunscrewing thecapnuts
(76C)usingthe adjust bolts(85).
f)Unscrewthe impellernuts(83). Removethe impellercollar(82), theimpeller(72).
g)Unscrewthe cap nuts(69C)and removethe vortexcasing(56).Takecarenotto
damage the threatof the shaft (29). Removethe packing (68)and the key(55).
h)Unscrewthe cap nuts(67C)and removethe deliverycover(71).Takecarenotto
damage the threatof the stud bolts(67A).

TOYOPUMPS EUROPE Edition 03.11.2009-8-
3. Disassemblingoftheshaft sealedsection
a)Unscrewthe setbolts(21)and removethe oil inletcovers(66)fromthe opening inthe
undercover(37). Collect the lubricationoilinarecipient.Removethe packings(65).
b)Unscrewthe bolts(35A)and removethe oilsealhousing B(61)usingthe adjustbolts
(35C). Removethe packing(62).
c)Removethe distancesleeve(54)and the O Ring (53).Removethe shaft sleeveB(51)
and the bearinglock plateB(48).
d)Unscrewthe setbolts(64A)and pullouttheoilchambercover(60)withtheadjust
bolts(64C). Removethe packing (63).
e)Fortaking outthe bearing (47),unscrewthe setbolts(59A),removethe bearingset
plate(46), andthenextract the bearingbypressure.
f)Removethe bearingsleeve(45)andunscrewthe setbolts(35A)toextracttheoil seal
housing A(58). Removethe packing (57).
g)Removethe O Ring (40)and theshaft sleeveA(44).
h)Removethe oilseals(41)(49),the Rareflon seals(43)(52)and the spacerings(42)(50)
fromthe housings(58)(61).
4. Disassemblingofthemotorsection
a)Set up the pumpup side down, posed on the uppercover.
b)Unscrewthe bottomcap nuts(32C)of the motorcase(28).
c)Liftup the undercover(37)rotor(30)and shaft (29)assemblyusing alifting device.
Separatethemfromthe motorcase(28)withhelpof theadjust bolts(32D).
d)Unscrewthe set bolts(35A)ofthe bearing cover(34).
e)Separateshaft (29)and rotor(30)fromthe undercover(37)usingalifting device.
f)Laydownthe shaft (29)withrotor(30)horizontallyandpulloutthe bearings(38)(39)
and the internalbushofthe bearing(23)withhelpof anappropriated extractor.
g)The wirescoming out ofthe statorhastobepreliminarydisconnected of the terminal
boardof the pump(see 1c)andthen unscrewthe uppercap nuts(32C)ofthe motor
case(28). Separatethemotorcase(28)withstator(31)fromthe uppercover(16)of
the pump. Removethe packing (19).
h)If necessary, pullout the bearingcoverA(26)and the externalbushof the bearing(23)
fromthe uppercover(16).

TOYOPUMPS EUROPE Edition 03.11.2009-9-
The disassembling of the pumpisnowfinished. Takecaretoclean allpartsbefore
reassemblingthem.
ASSEMBLING PROCEDURES
Toreassemblethepump,itissufficienttofollowthe disassemblingproceduresinopposite
direction. Pleasefind herebelowthe specificassembling instructions.
1. Bearings
a)The bearingsmaybe mounted bypression exerted on the internalring ofthebearing
bythe instrumentalityofajig.Donotforgettogreasethe shaft and the internalring of
the bearing beforemounting.
b)Nevertheless,itisrecommended toheatthebearingsbeforemounting.Inthiscase,
heatupthebearingsbyinductionorinoilatmaximum120°Cand slidethemon the
shaft. Afterwards,letthe bearingscooldownbyair.
c)Useonlygreaseforbearing lubrication orlithiumgrease.
2.Sealsinundercover
a)Verifythe condition oftheshaftsleevesAand B(44)(51)and theoilsealhousingA
and B(58)(61)beforebeginning theassemblyofthe pump.Replacethe shaft sleeves
if the surfaceisused, grooved, oreven showing the basemetal. Theirsurfaceneedsto
be rigorouslysmoothtoassurethe tightness.All sealsintothe undercoverhavetobe
replaced.
b)Attention,the sealshavetobe mounted sothatthe opening ofthe sealisshowing the
bottomof the oilsealhousing(impellerside).
The oilsealswillbe completelyfilled up withwater-resistantgreasebeforemounting
intothe oilsealhousing.
Putthe oil andRareflonsealsintothe oil sealhousing(58)-(61),andthisinthe same
orderasshownon the exploded view.Forthis,useahammerand ajig(schema1).
Neveruseahydraulicsystem.Proceed withcarebyexercising themostuniform
pressureaspossible.Adeformed sealloosesitsefficiency.Notraceof paintat allmay
be foundon theoilseal.

TOYOPUMPS EUROPE Edition 03.11.2009-10-
3.Otherseals
Renewallsealsafterdisassembling.
4. Clearance betweenimpellerandimpellerdisc
Unscrewthe cap nuts(76C).Pushthe impellerdisc (73)againstthe impeller(72)withthe
adjustbolts(85).Unscrewthe adjustbolts(85)withhalfaturn.Fasten thecap nuts(76C)
and the adjustbolts(85).Measuretheclearancebetween the impellerdisc and the
impeller.Thisclearancehastobe between 1.0and 1.5mm.Verifythe clearancewitha
gauge.Turntheshaftofthe pumpbyhand.Nofrictionisadmitted atall.Ifnecessary,
repeat the operation.
5. Electricconnection
Connect thepumpasshownon the drawingherebelow.
N.B. : Donotforgettofillup the undercoverwithoil.Therefore,usethe opening intothe
undercover. Type and oilquantityismentioned inthe technicalspecificationssheet
of the pump.