MT186e - V1.2

Teaching material
MT 186 Assembly and Maintenance

Exercise: Gear Pump
11/2008
MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Teaching material
Dipl.-Ing. Klaus-Jürgen Radtke

Dipl.-Geogr. Uta Linke
Version 1.2 Subject to technical alternations
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Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technological principles of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Classification and categorisation of pump types based on operating
principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Designs and operating characteristics. . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 GUNT Practice Line kits and their usage . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Operating characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4.1 Pump and system characteristics . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.3 Alteration of the operating point by restriction and variation
of speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.4 Operating characteristics of multiple interacting pumps . . . . 20
2.4.5 Intake characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . 21
3 Basics of pump maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.1 Definition Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Reasons for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Detection of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Checking pumps and replacing common wearing parts . . . . . . . . . . 27
3.5 Wearing parts in the pumps from the GUNT Practice Line for
assembly and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.6 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.7 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7.1 Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7.2 Shaft and piston rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.7.3 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.7.4 Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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4 Technical description Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.5 Gear pump dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.6 Spare parts drawing and spare parts list . . . . . . . . . . . . . . . . . . . . . . 50
5 Assembly and dismantling Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.1 Gear pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.1.1 Assembly stage 1 – Bearing flange, closed (assembly
unit 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.1.2 Assembly stage 2 – Housing (assembly unit 2) . . . . . . . . . . 55
5.1.3 Assembly stage 3 – Bearing flange, shaft (assembly unit 3) 57
5.1.4 Assembly stage 4 – Driven shaft (assembly unit 4) . . . . . . . 59
5.1.5 Assembly stage 5 – Drive shaft (assembly unit 5) . . . . . . . . 61
5.1.6 Assembly stage 6 – Housing . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1.7 Assembly stage 7 – Floating ring seal . . . . . . . . . . . . . . . . . 68
5.2 Dismantling the gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2.1 Dismantling assembly stage 7 – Floating ring seal. . . . . . . . 73
5.2.2 Dismantling assembly stage 6 – Housing . . . . . . . . . . . . . . . 74
5.2.3 Dismantling assembly stage 5 – Drive shaft . . . . . . . . . . . . . 75
5.2.4 Dismantling assembly stage 4 – Driven shaft . . . . . . . . . . . . 75
5.2.5 Dismantling assembly stage 3 – Bearing flange, shaft . . . . . 76
5.2.6 Dismantling assembly stage 2 – Housing . . . . . . . . . . . . . . . 76
5.2.7 Dismantling assembly stage 1 – Bearing flange, closed . . . 77
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6 Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.1 Worksheet 1, page 1: Introduction to the gear pump . . . . . . . . . . . . 81
6.2 Worksheet 2, page 1: Design, function and applications of gear
pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.3 Worksheet 3, page 1: Identifying causes of faults . . . . . . . . . . . . . . . 85
6.4 Worksheet 4, page 1: Sealing systems . . . . . . . . . . . . . . . . . . . . . . . 86
6.5 Worksheet 5, page 1: Inspection of pumps . . . . . . . . . . . . . . . . . . . . 88
6.6 Worksheet 6, page 1: Servicing pumps. . . . . . . . . . . . . . . . . . . . . . . 90
6.7 Worksheet 7, page 1: Repair of pumps . . . . . . . . . . . . . . . . . . . . . . . 92

6.8 Worksheet 8, page 1: Wearing parts on gear pump . . . . . . . . . . . . . 94
6.9 Worksheet 9, page 1: Assembling the gear pump. . . . . . . . . . . . . . . 95
6.10 Worksheet 10, page 1: Changing the floating ring seal. . . . . . . . . . . 99
6.11 Worksheet 11, page 1: Part identification using spare parts
drawing, familiarity with technical terms . . . . . . . . . . . . . . . . . . . . . 101
6.12 Worksheet 12, page 1: Spare parts ordering. . . . . . . . . . . . . . . . . . 103
7 Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.1 Worksheet 1, page 1: Introduction to the gear pump . . . . . . . . . . . 107
7.2 Worksheet 2, page 1: Design, function and applications of gear
pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.3 Worksheet 3, page 1: Identifying causes of faults . . . . . . . . . . . . . . 111
7.4 Worksheet 4, page 1: Sealing systems . . . . . . . . . . . . . . . . . . . . . . 112
7.5 Worksheet 5, page 1: Inspection of pumps . . . . . . . . . . . . . . . . . . . 114
7.6 Worksheet 6, page 1: Servicing pumps. . . . . . . . . . . . . . . . . . . . . . 116
7.7 Worksheet 7, page 1: Repair of pumps . . . . . . . . . . . . . . . . . . . . . . 118
7.8 Worksheet 8, page 1: Wearing parts on gear pump . . . . . . . . . . . . 120
7.9 Worksheet 9, page 1: Assembling the gear pump. . . . . . . . . . . . . . 121
7.10 Worksheet 10, page 1: Changing the floating ring seal. . . . . . . . . . 125
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7.11 Worksheet 11, page 1: Part identification using spare parts

drawing, familiarity with technical terms . . . . . . . . . . . . . . . . . . . . . 127
7.12 Worksheet 12, page 1: Spare parts ordering. . . . . . . . . . . . . . . . . . 129
8 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
9 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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1 Introduction
The MT 186 practice kit forms part of the GUNT learning concept for pump
maintenance, which is designed to aid education and training at trade acad-
emies and corporate training centres.
A close link between theory and practice is key to the learning content.
We offer the following products relating to the subject of pump assembly and
maintenance:
Pumps
Code Product
MT 180 Assembly and maintenance exercise - centrifugal pump
MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump
MT 182 Assembly and maintenance exercise - screw pump
MT 183 Assembly and maintenance exercise - diaphragm pump
MT 184 Assembly and maintenance exercise - piston pump
MT 185 Assembly and maintenance exercise - in-line centrifugal pump
MT 186 Assembly and maintenance exercise - gear pump
Tab. 1.1 Product relating to pump assembly and maintenance
This kit includes a gear pump.
Groups of two or three students working with one kit represents an optimal
way of learning.
1 Introduction 1
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The following learning content is covered:
Learning content / Exercises
Design and function of a gear pump
Assembly and disassembly, including for maintenance purposes
Replacing components (e.g. seals)
Reading and understanding engineering drawings and operating instructions
Comparing different pumps

(together with an additional kit forming part of this learning concept)
Tab. 1.2 Learning content / Exercises

The teaching material includes a technical description detailing the basics of

pumps and dealing with the related maintenance.
The pump included in this kit is presented and described. Its assembly and
disassembly is demonstrated.
This section of the teaching material is intended to help tutors in preparing
their own lessons. They may, of course, select information from it at their own
discretion to use in their teaching.
The kit also includes prepared exercise sheets for the students, followed by
the relevant solutions.
The appendix includes the complete set of drawings for the pump, in the form
of an assembly drawing with parts list, and including all manufacturing draw-
ings for the individual components.
We very much hope you enjoy using this GUNT assembly practice kit, and
we wish you success in your important task of providing students and appren-
tices with an introduction to the basic principles of the technology.
1 Introduction 2
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2 Technological principles of pumps
This chapter is designed to provide basic information for the following assem-
bly and maintenance exercises from GUNT.
Code Product
MT 180 Assembly and maintenance exercise - centrifugal pump
MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump
MT 182 Assembly and maintenance exercise - screw pump
MT 183 Assembly and maintenance exercise - diaphragm pump

MT 184 Assembly and maintenance exercise - piston pump
MT 185 Assembly and maintenance exercise - in-line centrifugal pump
MT 186 Assembly and maintenance exercise - gear pump
Wherever liquids are transported, produced or required to be supplied,

pumps are deployed. The demands which they must met vary widely. A vast
range of fluids has to be conveyed, from highly sensitive pharmaceuticals,
through large volumes of cooling liquid in power stations, to viscous chemical
products.
A wide variety of pumps have been developed over time for industrial
applications.
Not all pumps are mentioned in the following. Our outline presents a
structured guide to the most common types of pump.
2 Technological principles of pumps 3

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2.1 Classification and categorisation of pump types based on operating

principle
Pumps are fluid-flow machines which dictate how processes operate - that is
to say, they ensure that flow takes place within systems.
In practice, pumps are often named after the liquid they pump or their
purpose, such as milk pumps or cooling pumps. However, technicians and
fitters can more easily identify their design when they are named according
to their operating principle.
Fluid-flow machines
Machines Engines
(Machine drives a (Flowing medium
flowing medium) drives machine)
Pumps Turbines
Positive-displacement Centrifugal pumps

pumps (A gyro causes
(Medium conveyed by centrifugal forces to act
displacement device) on the medium)
Oscillating Rotating Normally priming Self-priming

Self-priming Self-priming (Not carrying gas, (Carrying gas,
(Displacement (Displacement pumping from low pumping from low
device moves device rotates in level restricted) level possible)
back and forth the pump body)
along an axis)
Piston pumps Gear pumps Centrifugal pumps Side-channel

pumps
Diaphragm pumps Screw Multi-stage
pumps centrifugal pumps
Inline pumps
Fig. 2.1 Pump types

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2.2 Designs and operating characteristics
The following table sets out the designs and operating characteristics of the
most common positive-displacement pumps.
The piston pump incorporates an oscillating piston

which is routed into a cylinder. The piston moves on an
axis. The pump body is blocked by intake and pressure
valves. A stroke gear drives the piston, which enlarges
or reduces the pump chamber on every stroke.
By enlarging the pump chamber, the pumped fluid is
drawn in by way of the intake valve. After a change of
stroke the pump chamber is reduced and the pumped

liquid is displaced by way of the pressure valve.
The diaphragm pump contains an elastomer

diaphragm which is clamped into the pump housing. The
oscillation is transferred from the stroke gear to the
diaphragm by way of a thrust rod. The fluid feeds in and
out by way of the valves, frequently executed as ball
valves.
The method of operation is the same as the piston
pump, with the diaphragm acting as the displacement
device.
The gear pump contains two opposite rotating rigid or

elastic gear wheels. The pump body is not closed off by
valves.
The liquid is pumped by the rotating gear wheels from
the intake to the delivery side in the gaps between the
teeth along the pump wall. The gear meshing and
narrow gaps between the rotor and housing minimise
the reflux.
The screw pump consists of two or more spindles with

helical splines which rotate inside a correspondingly
shaped housing. The pump body is not closed off by
valves.
The liquid is pumped axially in the free screw turns from
the intake to the delivery side.
Here too, as in the case of the gear pump, the sealing
from the delivery to the intake side is provided by narrow
gaps.

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The following table sets out the designs and operating characteristics of the
most common centrifugal pumps.
The centrifugal pump contains a rotating, enclosed

impeller with backward facing blades. The intake port is
axially aligned to the pump shaft. The delivery port is
aligned radially upwards.
The rotating impeller inside the pump body causes
centrifugal forces to act on the pumped liquid. The liquid
thrown out to the circumference of the pump by this
flows out of the pump through the delivery port.
The multi-stage centrifugal pump is similar in design

and action to the centrifugal pump. The difference is that
is features multiple impeller arranged in a row on a shaft.
The pumped liquid passes from the intake port via the
rotating impeller through a fixed guide channel to the
next impeller, and so on, until it reaches the delivery
port. The multistage impeller layout means the pump
attains higher delivery heads.
The inline centrifugal pump is similar in design and

method of operation to the centrifugal pump. Its intake
and delivery ports are along one axis however, though
here too the feed to the pump flows axially by way of an
appropriately shaped housing. The inline pump is used
in straight pipelines.

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Other special centrifugal pump designs
The side-channel pump contains a rotating starshaped

open impeller with radially running vanes. It rotates
inside a pump housing featuring a side channel which
narrows from the inlet to the outlet.
The energy transfer acts on the medium by means of an
exchange flow of the liquid in the impeller with that in the
side channel. The side channel pump thus operates
continuously with a self-priming effect, whereas the
centrifugal pump is not self-priming.
The canned motor pump is similar in design and action

to the centrifugal pump. It is leakage-free, as it requires
no shaft seal. The drive of the canned motor pump is
located practically inside the pump housing, and the
pumped liquid flows around it.
The magnetic clutch pump is similar in design and

action to the centrifugal pump. It is leakage-free and
requires no shaft seal.
The magnetic clutch pump is driven by a non-contact
magnetic clutch. The magnet on the pump shaft is inside
the pump housing. It is separated from the magnet on
the motor shaft by a tube.

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2.3 GUNT Practice Line kits and their usage
The GUNT Practice Line kits for assembly and maintenance exercises
include the following pumps:
MT 180 – Centrifugal pump

Fig. 2.2 Toolkit with parts set and pump
Fig. 2.3 Sectional drawing of the centrifugal pump
Centrifugal pumps are in widespread use, and are primarily used to pump
fluid media. Their applications include in shipbuilding, industry and water
supply.

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MT 181 – Multi-stage centrifugal pump

Fig. 2.5 Sectional drawing of a similar multi-stage centrifugal pump
The multi-stage centrifugal pump is modular in design, and is used to pump

fluid media at higher delivery pressures. It is used in water supply and in
industry.

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MT 182 – Screw pump

Fig. 2.7 Exploded-view drawing of the screw pump
Screw pumps are primarily used to transport viscous media such as lubricat-
ing oil, plant oil, glycols and polymers. Their applications include lubrication
systems for diesel engines and transmissions, as well as in hydraulic
systems.

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MT 183 – Diaphragm pump

Fig. 2.9 Sectional drawing of the diaphragm pump
Diaphragm pumps are absolutely leakage-free and, provided appropriate

materials are selected, are particularly well suited to pumping aggressive
fluids such as acids and caustic in chemical engineering applications.
Diaphragm pumps are often used for volumetric metering, as metering
pumps.

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MT 184 – Piston pump

Fig. 2.11 Drawing of the piston pump
Piston pumps are used primarily to transport fluids at high delivery pressures
and low flow rates. Typical applications include pumping drinking water and
domestic water in residential areas, in agriculture, onboard ships and in
industry.

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MT 185 – Inline centrifugal pump

Fig. 2.13 Exploded-view drawing of the in-line centrifugal pump
In-line centrifugal pumps are a sub-category of centrifugal pumps. Inline

pumps are installed in straight pipelines. They are required in applications
including water supply, watering and sprinkler systems, and in heating engi-
neering.

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MT 186 – Gear pump

Fig. 2.15 Exploded-view drawing of the gear pump
Gear pumps are of the rotating positive-displacement pump category, and

are characterised by pulsation-free delivery at operating pressures up to
40bar. High-viscosity media such as oils, paints and adhesives can be
pumped.

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2.4 Operating characteristics of pumps
Alongside preventive maintenance, repair work forms a key part of general

service operations. Damage to pumps can be traced back to incorrect oper-
ation in more than 50% of cases.
It is advantageous for the assembly personnel to have basic knowledge of
how the pump operates and are aware of how to use the pump correctly.
2.4.1 Pump and system characteristics
The delivery capacity of a pump is indicated by the pump’s characteristic

curve. The delivery rates are measured on the test stand at the respective
delivery pressures. The pump measurement data is depicted in the form of a
characteristic curve. Usually the delivery head is given in place of the deliv-
ery pressure (as a result the characteristic curves of centrifugal pumps are
not dependent on the density of the pumped liquid).
In the case of centrifugal pumps the dependency of the delivery rate on the
head is marked: As the head rises, the delivery rate decreases significantly.
By contrast, the delivery rate of positive-displacement pumps remains virtu-
ally constant as the head rises.
Head H
Head H
Delivery Q Delivery Q
Fig. 2.16 Characteristic curve for Fig. 2.17 Characteristic curve for
a centrifugal pump a positive-displacement
pump
In the case of positive-displacement pumps, it must be ensured that the

permissible operating pressure is not exceeded. Overflow valves are
frequently used for this.

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Operation of the positive-displacement pump with the overflow valve

(partially) open is depicted in the horizontal segment of the curve (see Fig.
2.17).
The graph gives an indication of the delivery capacity of the pumps, though
it provides no information on the delivery data actually achieved.
An often cited problem when operating pumps is that the pump does not
reach the necessary pressure. Generally speaking, pumps only deliver mate-
rial; the associated pressure is caused by the system.
The system operating data can likewise be measured and depicted graphi-
cally in the system characteristic curve. As the delivery rate increases, the
system pressure - determined by practical calculation - rises.

Head H
Delivery Q
Fig. 2.18 System characteristic curve

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2.4.2 Operating point
The actual delivery data result from the interaction of the pump and the
system.
If the pump and system curves are plotted on the same diagram, the point at
which the curves intersect is the operating point.
Head H
Head H
1
Fig. 2.19 Operating point (1) of a Fig. 2.20 Operating point (1) of a
normally priming centrifugal positive-displacement pump
pump
So if the operating data do not conform to the specification, the technician

should first check and calculate the correct operation of the pump in the
system. This should be done on initial commissioning and every time the
system is modified.

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2.4.3 Alteration of the operating point by restriction and variation of speed
In practice, restriction is frequently used to set the desired delivery rate. The
flow is restricted by partially closing a valve on the delivery side of the pump.
This results in a new system curve with a steeper rise. The new operating
point 2 is the point of intersection of the new system curve with the pump
curve. Or in other words: The operating point has shifted along the pump
curve from 1 to 2.
While the delivery rate decreases as the head rises on a centrifugal pump,
the delivery of a positive-displacement pump remains constant as the
pressure rises.
Head H
Head H
1
1
Fig. 2.21 Shift in operating point from Fig. 2.22 Shift in operating point from
(1) to (2) by restriction for a (1) to (2) by restriction for a
normally priming centrifugal pump positive-displacement pump

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A common method of shifting the operating point of a pump is to vary the

speed. The speed is varied by means of an adjuster gear or a frequency
inverter. This produces a new pump characteristic curve.
The diagrams show an increase in speed from n1 to n2 for both pump types
(see Fig. 2.23 and Fig. 2.24). In the case of the centrifugal pump, the pump
curve moves upwards, while for the positive-displacement pump it shifts to
the right.
In both diagrams the operating point shifts upwards along the system curve.
That is to say, higher heads and delivery rates are produced as the speed
increases.
Head H
Head H
n2
n1 n2
n1
Fig. 2.23 Influence on the pump Fig. 2.24 Influence on the pump
characteristic of a variation in characteristic of a variation in
speed for a normally priming speed for a positive-
centrifugal pump displacement pump

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2.4.4 Operating characteristics of multiple interacting pumps
Operation of multiple pumps simultaneously in a system is quite common,

and in many cases essential in order to conform to extreme operating speci-
fications.
If multiple pumps are configured in parallel, the delivery rate is increased. If
pumps are configured in series (one behind the other), the delivery heads
are added together.
Fig. 2.25 Parallel configuration Fig. 2.26 Series configuration
The pump industry has made use of these properties and developed a
number of designs accordingly.
Multi-flow pumps achieve high delivery rates, multi-stage pumps achieve
high heads.
Fig. 2.27 Multi-flow pump, sectional Fig. 2.28 Multiple-stage pump, sectional
view and delivery principle view and delivery principle

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2.4.5 Intake characteristics of pumps
Attention must be paid to the intake characteristics of the pumps. A distinc-

tion is made between selfpriming and nonselfpriming pumps.
The normally priming centrifugal pump is a non-self-priming pump. It is not
capable of pumping a gaseous medium out of the pump body. It must always
be ensured that a liquid is fed in from a higher level, or where the feed is from
a lower level, the liquid head does not collapse, such as due to the use of foot
valves on the intake side.
Fig. 2.29 Infeed of a pump system for a normally priming pump

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Self-priming pumps include side channel pumps (see chapter 2.2, page 5).
They are capable of pumping gases. However, the pump body must always
be filled with liquid for this to happen. That is why the intake and delivery ports
on side channel pumps always point upwards.
Fig. 2.30 Intake of a pump system for a self-priming pump
Most positive-displacement pumps are self-priming. The displacement

device is able to compress the gas and displace it out of the pump body. For
this to happen, however, the pump must be partially filled with liquid, because
only wetted valves close exactly such that no reflux is possible. This also
applies to rotating positive-displacement pumps, of which the wetted gaps
restrict reflux.

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3 Basics of pump maintenance
3.1 Definition Maintenance
All pump operators should maintain their pumps in accordance with the main-
tenance and operating instructions issued by the manufacturers. Mainte-
nance is the umbrella term for inspection, servicing and repair (see Fig. 3.1).
A log book or machine file should be set up for each pump unit, indicating the
current status and the repair work carried out to date.
MAINTENANCE TO DIN 31051

Inspection Servicing Repairs
Recording and Preservation of the Restoration of the

assessment of the specified status specified status
current actual status
Measurement, Cleaning, Replacement,

Testing, Lubrication, Correction
Diagnosis Adjustment
With the system Only with Only with the system

running and at stand system stopped stopped, based on
still based on according to specific work order and
inspection instructions maintenance after careful preparation
instructions
Fig. 3.1 Maintenance
3 Basics of pump maintenance 23

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3.2 Reasons for maintenance
Pumps are required for the operations of many manufacturing systems. If the
pumps are malfunctioning, there is a risk of production outages. Appropriate
maintenance is a key factor determining the productivity of operations.
Complete replacement of the pump is possible in the event of a defect,
though it is not always essential and, especially, is not necessarily cost-effec-
tive. Carrying out preventive maintenance and servicing, as well as repairs,
is advantageous. A number of reasons are cited by way of example.
• The cost of purchasing a mid-sized industrial pump is considerable. The
annual cost of wearing parts amounts to around 10% - 20% of the
purchase price of the new pump.

• Holding a complete replacement pump in stock is inefficient and expensive
for many businesses. It is, however affordable, and advisable, to hold
stocks of key pump spares.
• The delivery lead times for complete pumps are usually lengthy, whereas
spares can be supplied from suppliers’ central stores at short notice.
1
Cost
Service life
Fig. 3.2 Total cost, comparison of replacement (1) and maintenance (2)
• Fig. 3.2 shows that routine maintenance of pumps (2) results in lower costs
in the medium and long term than complete replacement of pumps (1).

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3.3 Detection of faults
Many factors need to be considered in order to ensure optimised, trouble-free

operation of pumps. Nevertheless, faults will routinely occur. A number of
basic points need to be observed in order to assess faults and their causes:
• The specifications of the delivery medium need to be considered in order
to ensure long service life of the pumps. The material durability of the
pump components and seals must be ensured. The design and construc-
tion of the pump must be attuned to the specific pumping requirements.
• Most pumps are driven by electric motors. Attention must be paid to
correct dimensioning and selection.
• Incorrect electrical connections and setting the incorrect direction of

rotation are often sources of faults resulting in production problems.
• As a general rule applicable to all pumps, lengthy periods of dry running
should be avoided, as this would substantially shorten the service lives of
the shaft seal, piston seal and valves. The delivery medium provides
additional lubrication of those components. This principle is illustrated by
the example of the floating ring seal in Fig. 3.3.
Fig. 3.3 Floating ring seal with liquid film
There must always be a liquid film between the contact faces of a floating ring
seal.

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During inspection of the pump, checks should be made regularly while the
pump is running to ensure early detection of faults, focussing in particular on
the following points:
• Leakage
• Noise
• Smooth running
• Temperature
• General condition
The reasons for pump faults are many and varied.
System-related disturbances such as pressure surges should be avoided or

eliminated. Incorrectly switching system valves may stop the pumped liquid
to an extreme degree, causing overlaid liquid waves to form which result in
pressure surging as far as into the pump.
Trapped foreign bodies cause significant damage inside the pump.
Deformed shafts, destroyed bearings and valves, as well as scraping impel-
lers, are the consequences of such disturbances. Even tiny abrasive particles
will cause long-term damage to the pump and the seals.
The occurrence of cavitation is a system fault which needs to be prevented.
If the infeed line to the pump is incorrectly dimensioned, it is possible that a
vacuum will created in the intake port, causing the medium to boil. The
increase in pressure in the pump causes the boiling bubbles to implode,
thereby destroying the housing and impeller.
Fig. 3.4 Cavitation damage to a pump impeller

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3.4 Checking pumps and replacing common wearing parts
In accordance with the service intervals specified in the manufacturers’ main-

tenance instructions, which are additionally dependent on the specific oper-
ating conditions, it is advisable to check pumps about once a year.
Bearings
The operating instructions specify that the lubricant should be changed on
pumps with an enclosed gear and bearing unit.
Modern-day greased bearings are lifetime-lubricated, and merely need to be
checked for smooth running.
Shaft seals
Packing glands and floating ring seals are checked for leaks and wear.
Glands can be adjusted, if still possible. The gland packing should be
replaced after about 2000 operating hours.
The service lives of the floating ring seals are considerably longer. They are
replaced in full if worn.
Couplings
Pumps coupled to their drives by flexible couplings should be checked for
flush coupling. The power-transmitting components should be checked for
wear and replaced as necessary.

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Pump internals
The pumps should be opened and their internals checked for wear and
corrosion at the specified servicing intervals.
In the case of centrifugal pumps, as well as the shaft seal the static seal ring
must be checked and replaced if worn.
The valves of reciprocating pumps, including their sealing faces, should be
checked. Piston rings and packing should be checked for wear, and the
plungers and sleeves checked for scoring.
20
Pump internals Shaft seal
Bearing Coupling
Fig. 3.5 Pump unit with listed wearing part groups

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3.5 Wearing parts in the pumps from the GUNT Practice Line for assembly
and maintenance
It should be stated by way of preamble that, according to the state of the art
in centrifugal pumps, bearings are no longer classed as wearing parts.
MT 180 – Centrifugal pump
Housing seal Shaft seal

(gland)
Fig. 3.6 Sectional drawing of the centrifugal pump
MT 181 – Multi-stage centrifugal pump

Packing gland Housing/stage seal Floating ring seal
Fig. 3.7 Sectional drawing of a similar multi-stage centrifugal pump

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MT 182 – Screw pump

Housing seal Housing seal
Floating ring seal
Fig. 3.8 Exploded-view drawing of the screw pump
MT 183 – Diaphragm pump
Valves
Diaphragm
Oil filling Journal bearing

Fig. 3.9 Sectional drawing of the diaphragm pump
The wearing parts mentioned should be replaced during servicing.

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MT 184 – Piston pump
Piston rod seal
Valves
Oil filling Piston seal
Fig. 3.10 Drawing of the piston pump
MT 185 – Inline centrifugal pump
Housing seal Floating ring seal
Fig. 3.11 Exploded-view drawing of the in-line centrifugal pump
Wear is to be expected on the parts marked, necessitating replacement of

them.

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MT 186 – Gear pump
O-rings
Floating ring seal

Wear disc Journal bearing Housing seal
Fig. 3.12 Sectional drawing of the gear pump
Any well organised maintenance department should hold stocks of the

wearing parts on the various pumps mentioned in this chapter.

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3.6 Shutdown
In systems in which uninterrupted running of pumps is extremely important,

such as in power stations or onboard ships, replacement units are installed
fully piped-up as standby units. This allows servicing or repairs to be carried
out during live operation, by switching to the standby unit.
Fig. 3.13 Installation with standby Fig. 3.14 Single pump with stop
pump valves
In most production environments, maintenance can only be carried out during

production downtimes - that is, at partial or complete standstill. The pumps
should be integrated into the system in such a way that short-interval servic-
ing can be carried out without removing them. That is to say, they must be
easily accessible for inspection and servicing. On the pump intake side and
the delivery side stop valves should be installed.
In the case of positive-displacement pumps, the drive unit is first shut down.
Immediately after the pump stops the delivery-side valve is closed, then the
intake side is closed. If non-return valves are installed, they automatically act
as stop valves. So installed non-return valves on the delivery side, for exam-
ple, prevent possible reflux to the pump.
In the case of centrifugal pumps, the delivery-side valve is first closed, then
the drive is shut down, and then the intake side is closed.
Before opening the pump, the pump and the connected piping system must
be drained. This can be done either by way of sealing plugs or by carefully
detaching the pipe fittings.
If the pump unit is removed completely from the system for major mainte-
nance work, the safety guidelines issued by the drive manufacturers must
additionally be followed.

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3.7 Repairs
Whereas during servicing parts are usually replaced following checking and
as required, during repair complete wearing parts or defective components
are replaced after predetermined operating cycles. These cycles are either
specified by the manufacturers or they are determined by the identified
condition of parts at the various maintenance intervals.
It is advisable to schedule every second to third service as a repair operation.
3.7.1 Static seals

Flat seals and O-rings used for sealing between metal components and to
prevent escape of liquid from the pump body are replaced completely. Their
locations include at the connection fittings and on the housing covers, floating
ring seals, shaft sleeves and valves.
Procedure:
• Dismount the pump
• Remove the seals and dispose of them
• Clean the parts
• Install the new seals during reassembly
• Avoid mechanical damage. Ensure cleanliness.
Grease seals where necessary.

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Static seal
Static seals
Static seals
Fig. 3.15 O-rings in a centrifugal pump

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3.7.2 Shaft and piston rod seals
The most varied stresses on seals in pump engineering occur in the sealing
of shaft and piston rod feed-throughs. These seals must act between areas
subject to different pressures, and are subject to the demands of a wide
variety of media, as well as having to withstand additional physical strains
caused by rotating shafts or oscillating piston rods. These types of seal are
known in engineering as dynamic seals. Operators expect reliable sealing,
with minimal leakage, over a long service life. The shaft seals in particular
should be preventively replaced during scheduled repair work, because of
the extreme stresses to which they are subject.
Piston rod seal
Fig. 3.16 Example of a piston rod seal
Shaft seal
Fig. 3.17 Example of a shaft seal

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A tried and proven method of sealing shafts is by means of soft packing

glands.
This packing consists of a woven cord made principally of solid fabrics which
is inserted in the packing space between the shaft and the housing, where it
is deformed by an axial force and so moulded to the surfaces it is intended to
seal.
1 3
4
Fig. 3.18 Example of a gland Fig. 3.19 Packing gland packing
To seal the pump shaft, packing glands (1) are used. These are provided in
a wide range of materials and designs depending on the pump application.
To protect the shaft, a shaft sleeve (2) is installed. Locking rings or ancillary
glands (3) hold the packing in place. The gland press (4) compresses the
packing by way of screw fittings. Correct functioning demands careful assem-
bly and commissioning.

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Item Name
1 Washer
2 Shaft
3 Packing gland packing
4 Locking ring
5 Packing gland press
6 Stud bolt with

hexagonal nut
7 Shaft sleeve
8 Housing cover
Fig. 3.20 Packing gland of a centrifugal pump, sectional view with zoom
When packing a new gland the following points need to be considered:

• Correct choice of packing based on quality and dimensions
• Completely remove old packing residues (3)
• The shaft protective sleeve (7) must be free of surface damage
• Insert the packing (3) with offset interfaces
• Use of sharp tools will damage the gland
• Tighten the gland press (5) by screws after inserting the packing, then
slacken it slightly
• The pump shaft (2) must be loose enough to be turned slightly by hand

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• Only tighten up the gland press after a run-in time of about 20-30 minutes
with leakage of 50-100 drops per minute
• Adjust the gland to the required leakage rate of 3 drops per minute
To seal shaft lead-throughs which are subject to high stresses, floating ring
seals are the most advantageous option nowadays. They are available in a
wide range of designs, dimensions and frictional material pairings. Correctly
selected, fitted and operated floating ring seals will permit longer-lasting
operation of rotating positive-displacement and centrifugal pumps, with less
leakage, then packing glands.
3 2 4 1
Fig. 3.21 Drawing of a floating ring seal
Floating ring seals are contact seals which create a yielding seal connection
between stationary and rotating contact faces. Between the contact faces is
a film of liquid, which assumes a stable position due to the centrifugal force
occurring during rotation. The floating ring seal is sealed against the housing
by means of static elastomer seals (1). The floating ring (2) rotating with the
shaft is held axially in place relative to the counter-ring (4) fixed in the housing
by a spring (3). The contact faces thus automatically adjust axially. Even high
pressures can be controlled by means of hydraulic relief.

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Fig. 3.22 Floating ring seal
Procedure for replacing the floating ring seal on a centrifugal pump shown
below:
• Shut down the pump
• Open the pump cover (1)
• Slacken the impeller nut (2)
• Detach the impeller (3) from the shaft
• Remove the floating ring (4) from the shaft
• Pull the counter-ring (5) out of the housing using a suitable implement
• Assemble in the reverse order of removal
4
1
3
5
2
Fig. 3.23 Example of replacing a floating ring seal on a centrifugal pump

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In view of the wide range of floating ring seal designs and pump versions,
methods of removal and fitting vary. The principle illustrated here is that appli-
cable to the most frequently used centrifugal pump.
The piston rod sealing in oscillating motions of the piston rods and plungers
of the piston pumps is achieved by using packing glands, lipped rings,
grooved rings (1) and conical rings held in support rings (2). The design and
materials must always be selected to match the given operating conditions.
Spring-loaded (3) seals, for example, offer uniform pre-tension, low friction
and so longer service lives.
3 1 2
Fig. 3.24 Drawing of a piston rod seal
The method of removal and fitting depends on the specific pump version and
design. The manufacturers’ fitting instructions are useful in this context, and
should be followed.

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The same is true of the piston seals. Replacing piston rings and piston
sleeves forms part of the essential scheduled repair routine. Some design
variants are shown in Fig. 3.25.
Piston with hemp stricks Piston with leather/rubber Piston with metal seal
sleeves rings
Fig. 3.25 Examples of piston seals

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3.7.3 Valves
Positive-displacement pumps such as reciprocating pumps and diaphragm

pumps seal off the delivery space by means of intake and delivery side
pressure valves. They open due to the resultant pressure difference on every
stroke and close due to their intrinsic mass or by additional spring force.
The valves of the smaller diaphragm pumps, used as metering pumps in the
chemical industry, are executed as ball valves. Owing to the more precise
effect achieved, twin ball valves are often installed. They are replaced by
simply unscrewing the valve unit out of the housing.
Fig. 3.26 Twin ball valve of a diaphragm pump
The valves of the piston pumps may be executed as weight or spring-loaded

disc valves.
The sealing faces are mostly metallic, and correspondingly sensitive.
After being individually removed, the discs are replaced. The valve seats are
checked and re-milled or lapped as necessary. In the case of valves with an
additional elastomer sealing disc, only the disc needs to be replaced, and the
smooth running checked.

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Weighted with conical Spring-loaded with flat Spring-loaded with flat seat
seat seat and seal ring
Fig. 3.27 Examples of disc valves
3.7.4 Spare parts ordering
Maintenance work should generally be carried out on a routine basis in

accordance with the maintenance instructions and safety rules laid down by
the manufacturers. Key parts should be replaced at the maintenance inter-
vals indicated in the operational or machine log. Arrangements should be
made for parts to be procured from the supplier in advance.
Every pump has a rating plate affixed to it by the manufacturer. The rating
plate indicates the manufacturer’s name, the pump model and serial number.
The data is often also imprinted on the housing, so the information is still
available even if the rating plate comes off. Based on this information, the
exact technical and material specification can be identified.

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Fig. 3.28 Example of a housing with imprinted model and serial number
The details shown in Fig. 3.29 need to be quoted to the supplier when order-
ing spares, so as to ensure the correct parts are supplied:
1. Pump model
2. Serial number
3. Part name
4. Item number on parts list
Fig. 3.29 Information for spare parts ordering, e.g. identified from rating plate, parts
drawing or parts list

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4 Technical description Gear pump

Fig. 4.1 Gear pump
4.1 Description
Gear pumps are rotary positive displacement pumps, which operate on the
positive displacement principle.
They have a clear design and are easy to handle. Gear pumps can generate
operating pressures of up to 40bar and delivery flows of up to 60 m3/h. Their
pulse-free delivery flow increases linearly with the speed. High-viscosity
media (oils, paints, adhesives, etc.) can also be pumped.
Gear pumps are sensitive to hard solid particles in the flow. The stainless
steel material used in the construction of the pump presented here make it
resistant to most corrosive and aggressive chemicals. The plastic / metal
gear wheel pairing results in relatively quiet running.
4.2 Mode of operation
The gear pump is powered by the drive shaft located below it. The PTFE gear
wheel located above is carried along by the lower stainless steel gear wheel.
4 Technical description Gear pump 46

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The rotating gear wheels convey the pumped liquid in a circumferential

direction along the surrounding housing, from the intake to the delivery side.
Working valves are not required. The intake and delivery sides are separated
by a sealing gap.
Fig. 4.2 Gear pump delivery principle
The delivery direction can be reversed by changing the direction of rotation.

Looking at the drive shaft, with clockwise rotation the right-hand fitting is the
intake fitting.
The gear pump is self-priming. However, it must not be run dry, so as to
prevent wear and preserve the sealing.
Fig. 4.3 Clockwise rotation of drive shaft – right-hand fitting is intake fitting

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4.3 Layout
The layout of the gear pump is shown in the drawings. The pump consists of
the following assemblies:
• Bearing flange, closed (1)
• Housing (2)
• Bearing flange, shaft (3)
• Driven shaft (4)
• Drive shaft (5)
• Floating ring seal (7)
The shafts have a floating design in PTFE plain bearing bushes using wear
discs.
The gear wheels are fastened to the shafts with a feather key and snap ring.
The two bearing flanges are fastened to the housing with through bolts.
O-rings are used to seal the housing.
The shaft seal takes the form of a floating ring seal.
6
1 3
7
Fig. 4.4 Exploded drawing with gear pump assemblies

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4.4 Technical data
• Pump model: Liquiflo, No. 35155-1-2

• Power consumption: max. 2 kW
• Max. capacity: 80l/min
• Max. delivery pressure: 7bar
• Motor speed: 300...1750rpm
• Intake connection thread: R 1¼“
• Pressure connection thread: R 1¼“
• Pump materials:
Housing: Stainless steel 316 (1.4401)
Gear wheels: Stainless steel 316 (1.4401)/PTFE
Wear discs: PTFE
Bearings: PTFE
• Speed-dependent viscosity:
n=300rpm: 10000mPas
n=1750rpm: 3000mPas
4.5 Gear pump dimensions
11/4" BSPT
105,8
54
35
ø15,7
32 66,6
190 81 ø7,1
265 101,6
Fig. 4.5 Dimensional drawing

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4.6 Spare parts drawing and spare parts list

Fig. 4.6 Spare parts drawing

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Item Quantity Unit Name Item number / Comments

Standard
1 1 Piece Housing MT186.10.01.001 X4CrNiMo17-12-2
2 1 Piece Bearing flange, closed MT186.10.01.002 X4CrNiMo17-12-2
3 1 Piece Bearing flange, shaft MT186.10.01.003 X4CrNiMo17-12-2
4 1 Piece Seat ring MT186.10.01.004 X4CrNiMo17-12-2
5 1 Piece Drive shaft MT186.10.01.005 X4CrNiMo17-12-2
6 1 Piece Driven shaft MT186.10.01.006 X4CrNiMo17-12-2
7 2 Piece Screw plug MT186.10.01.007 X4CrNiMo17-12-2

8 1 Piece Driving gear MT186.10.01.008 X4CrNiMo17-12-2
9 1 Piece Driven gear MT186.10.01.009 PTFE
10 4 Piece Plain bearing bush MT186.10.01.010 PTFE
11 4 Piece Locking pin MT186.10.01.011 PTFE
12 1 Piece Solid ring MT186.10.01.012 Ceramic
13 4 Piece Wear disc MT186.10.01.013 PTFE
14 2 Piece Housing seal MT186.10.01.014 PTFE
15 4 Piece Housing pin MT186.10.01.015 NiCr20CuMo
16 2 Piece O-ring 128x2
17 2 Piece Feather key 4.76x4.76x41.28 [0.187“x0.187“x1.63]
18 1 Piece Floating ring seal
19 2 Piece Hexagon screw 1/4“–28x1 HHCS 18-8SST
20 4 Piece Hexagon nut 1/4–20 18-8SST
21 4 Piece Hexagon screw 1/4–20x3 3/4 18-8SST
22 6 Piece Spring washer 1/4“ 18–8SST 18-8SST
23 4 Piece Snap ring DIN 7993–A16
Tab. 4.1 Spare parts list

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5 Assembly and dismantling Gear pump
5.1 Gear pump assembly
The gear pump assembly procedure is divided into seven stages:

• Assembly stage 1 – Bearing flange, closed (assembly unit 1)
• Assembly stage 2 – Housing (assembly unit 2)
• Assembly stage 3 – Bearing flange, shaft (assembly unit 3)
• Assembly stage 4 – Driven shaft (assembly unit 4)
• Assembly stage 5 – Drive shaft (assembly unit 5)
• Assembly stage 6 - Housing

• Assembly stage 7 – Floating ring seal
Tools:
• Combination wrench, size 11
• Hexagon socket wrench SW 3/32”
• Screwdriver
5 Assembly and dismantling Gear pump 52

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5.1.1 Assembly stage 1 – Bearing flange, closed (assembly unit 1)
11
2
Item Name
10
2 Bearing flange, closed
10 Plain bearing bush
11 Locking pin
Fig. 5.1 Bearing flange, closed drawing (assembly unit 1)
10
11
Bearing flange, closed, fully Parts required for assembly
assembled (assembly unit 1)

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Procedure for assembling the bearing flange, closed (assembly unit 1)
Bearing flange,
closed
(2)
Plain bearing hush

(10)
Locking pin
(11)
Bearing flange,
closed
(assembly unit 1)
Assembly procedure for bearing flange, closed (assembly unit 1)

Assembly procedure:
• Insert the plain bearing bush (10) in the closed bearing flange (2). Turn the
bearing bush until the groove is flush with the groove in the flange.
• Insert the locking pin (11) into the grooves.
• Repeat this procedure for the second bearing bush

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5.1.2 Assembly stage 2 – Housing (assembly unit 2)
16
15 Item Name
1 Housing
16 O-ring
15 Housing pin
Fig. 5.2 Housing drawing (assembly unit 2)
15
16
Housing, fully assembled Parts required for assembly

(assembly unit 2)

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Procedure for assembling the housing (assembly unit 2)
Housing
(1)
O-rings
(16)
Housing pins
(15)
Assembly unit 2
Assembly procedure for housing (assembly unit 2)

Assembly procedure:
• Place the two O-rings (16) in the O-ring grooves in the housing (1).
• Insert the four housing pins (15) in the relevant holes on the front of the
housing (1).

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5.1.3 Assembly stage 3 – Bearing flange, shaft (assembly unit 3)
11
10
Item Name
3 Bearing flange, shaft

3
11 Locking pin
Fig. 5.3 Bearing flange, shaft drawing (assembly unit 3)
3
10
11
Bearing flange, shaft, fully

assembled (assembly unit 3) Parts required for assembly

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Procedure for assembling the bearing flange, shaft (assembly unit 3)
Bearing flange, shaft

(3)
Plain bearing hush

(10)
Locking pin
(11)
Bearing flange,
shaft
(assembly unit 3)
Assembly procedure for bearing flange, shaft (assembly unit 3)

Assembly procedure:
• Insert the plain bearing bush (10) in the shaft bearing flange (3). Turn the
bearing bush until the groove is flush with the groove in the flange.
• Insert the locking pin (11) into the grooves.

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5.1.4 Assembly stage 4 – Driven shaft (assembly unit 4)
9 17
6
23
Item Name
6 Driven shaft
17 Feather key
9 Driven gear
23 Snap ring
Fig. 5.4 Driven shaft drawing (assembly unit 4)
6 9
17
23
Driven shaft, fully assembled Parts required for assembly
(assembly unit 4)

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Procedure for assembling the driven shaft (assembly unit 4)
Driven shaft (6)
Feather key
(17)
Driven gear
(9)
Snap ring (23)
Driven shaft
(assembly unit 4)
Assembly procedure for driven shaft (assembly unit 4)

Assembly procedure:
• Place the feather key (17) in the groove on the driven shaft (6).
• Slide the driven gear (9) over the shaft (6) and feather key (17). The
feather key is now also positioned in the groove on the gear.
• Slide the two snap rings (23) over each end of the shaft as far as the
appropriate shaft groove and click into place.

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5.1.5 Assembly stage 5 – Drive shaft (assembly unit 5)
8 17
5
23
Item Name
5 Drive shaft
17 Feather key
8 Driving gear
23 Snap ring
Fig. 5.5 Drive shaft drawing (assembly unit 5)
Drive shaft, fully assembled (assembly unit 5)
8
5
17 23
Parts required for assembly

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Procedure for assembling the drive shaft (assembly unit 5)
Drive shaft
(5)
Feather key
(17)
Driving gear
(8)
Snap ring (23)
Assembly unit 5
Assembly procedure for drive shaft (assembly unit 5)

Assembly procedure:
• Place the feather key (17) in the groove on the drive shaft (5).
• Slide the driving gear (8) over the shaft (5) and feather key (17). The
feather key is now also positioned in the groove on the gear.
• Slide the two snap rings (23) over each end of the shaft as far as the
appropriate shaft groove and click into place.

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5.1.6 Assembly stage 6 – Housing
20 22 21 13
5
1 2 3
Item Name
1 Assembly unit 1
2 Assembly unit 2
3 Assembly unit 3
4 Assembly unit 4
5 Assembly unit 5
13 Wear disc
21 Hexagon screw
22 Spring washer
20 Hexagon nut
Fig. 5.6 Housing assembly drawing

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Pump housing, fully assembled
2 3
4
13
21 20
22

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Procedure for housing assembly 6
Housing
(assembly unit 2)
Drive shaft
(assembly unit 5)
Driven shaft
(assembly unit 4)
Wear disc
(13)
Bearing flange,
closed
(assembly unit 1)
Bearing flange,
shaft
(assembly unit 3)
Hexagon
screw fitting
(20, 21, 22)
Housing

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Assembly procedure for housing

Assembly procedure:
• Place the drive shaft (assembly unit 5) in the lower half of the housing
(assembly unit 2) with the long end of the shaft to the right.
• Place the driven shaft (assembly unit 4) in the upper half of the housing
(assembly unit 2).
Installing the driven shaft
• Slide one wear disc (13) over each end of the shaft with the smooth side
towards the gear into the housing. The cut sides point towards one
another.
Assembly of wear discs

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• Place the closed bearing flange (assembly unit 1) onto the left side of the
housing (1). Carefully insert the shaft ends into the floating bearing bushes
(10) without sliding the shaft out of the housing. The housing pins (15)
engage in the holes in the bearing flange.
• Place the shaft bearing flange (assembly unit 3) onto the right side of the
housing (1). Carefully insert the shaft ends into the floating bearing bushes
(10) without sliding the shaft out of the housing. The continuous bearing
bush is placed over the long end of the shaft. The housing pins (15)
engage in the holes in the bearing flange.
Attaching the shaft bearing flange
• Run the four hexagon screws (21) through the holes in the bearing flange
and the housing and fit with spring washers (22) and hexagon nuts (20).
Tighten the screws crosswise.

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5.1.7 Assembly stage 7 – Floating ring seal
18 4
14
12
19, 22
7
Item Name
1 Housing assembly 6
18 Floating ring seal
12 Solid ring
14 Housing seal
4 Seat ring
19 Hexagon screw
22 Spring washer
7 Screw plug
Teflon strip
Fig. 5.7 Floating ring seal assembly drawing

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Floating ring seal, fully assembled
12
14
18
7
22 19 4

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Procedure for floating ring seal assembly 7
Housing
Floating ring seal

(18)
Housing seal
(14)
Solid ring
(12)
Seat ring
(4)
Hexagon
screw fitting
(19, 22)
Teflon tape
Screw plug
(7)
Gear pump

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Assembly procedure for floating ring seal

Assembly procedure:
• Slide the floating ring seal (18) over the shaft into the shaft bearing flange
(3) until the hexagon screw is visible through the threaded hole for the
screw plug (7). Tighten the screw with the hexagon socket wrench. Turn
the shaft manually until the other hexagon screws are visible, tighten and
thus fasten the floating ring seal to the shaft.
Assembly of floating ring seal
Hexagon screw on floating ring seal Tightening the floating ring seal
• Slide a housing seal (14) onto each side of the solid ring (12).
• Slide the solid ring (12) over the shaft against the shaft bearing flange (3).

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Assembly of solid ring
• Slide the seat ring (4) over the shaft and solid ring (12) against the shaft
bearing flange (3).
Assembly of seat ring
• Screw the seat ring against the bearing flange with hexagon screws (19)
and spring washer (22). Tighten the screws uniformly.
• Wind two to three layers of Teflon tape around the thread of the screw
plugs (7).
• Twist the screw plugs (7) into the threaded hole on the shaft bearing flange
and tighten lightly.

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5.2 Dismantling the gear pump
Tools:
• Combination wrench, size 11
• Hexagon socket wrench SW 3/32”
• Screwdriver
5.2.1 Dismantling assembly stage 7 – Floating ring seal
• Loosen the hexagon screws (19) and spring washer (22) and uniformly
screw out of the shaft bearing flange (3).

• Remove the seat ring (4) from the drive shaft (5) and solid ring (12).
• Remove the solid ring (12) from the drive shaft (5) with housing seal (14)
from the shaft.
• Remove the housing seal (14) from the solid ring and bearing flange.
• Loosen the screw plugs (7) and twist out of the threaded hole on the shaft
bearing flange.
• Turn the shaft manually until the hexagon screws for the floating ring seal
(18) are visible through the threaded hole for the screw plug (7). Loosen
all four screws. Carefully slide the floating ring seal out of the bearing
flange with a screwdriver through the screw plug hole. Remove the floating
ring seal from the shaft.
Floating ring seal dismantled

11/2008
5.2.2 Dismantling assembly stage 6 – Housing
• Loosen the four hexagon screw fittings (20, 21, 22) and remove the
hexagon screws from the bearing flange and housing holes.
• Carefully detach the shaft bearing flange (assembly unit 3) from the right
side of the housing with a screwdriver. Remove assembly unit 3 from the
shaft.
• Carefully detach the closed bearing flange (assembly unit 1) from the left
side of the housing with a screwdriver. Remove assembly unit 1 from the
shaft.
• Remove the wear discs (13) from the ends of the shaft.
• Remove the driven shaft (assembly unit 4) from the upper half of the
housing (assembly unit 2).
• Remove the drive shaft (assembly unit 5) from the lower half of the housing
(assembly unit 2).
Pump housing dismantled

11/2008
5.2.3 Dismantling assembly stage 5 – Drive shaft
• Prise the two snap rings (23) out of the groove with a screwdriver and
remove from the relevant end of the shaft.
• Remove the driving gear (8) from the drive shaft (5) and feather key (17).
• Remove the feather key (17) from the groove on the drive shaft (5).
Drive shaft dismantled
5.2.4 Dismantling assembly stage 4 – Driven shaft
• Prise the two snap rings (23) out of the groove with a screwdriver and
remove from the relevant end of the shaft.
• Remove the driven gear (9) from the shaft (6) and feather key (17).
• Remove the feather key (17) from the groove on the shaft (6).
Driven shaft dismantled

11/2008
5.2.5 Dismantling assembly stage 3 – Bearing flange, shaft
• Remove the plain bearing bush (10) from the shaft bearing flange (3).
• Remove the locking pin (11) from the groove.
Bearing flange, shaft dismantled
5.2.6 Dismantling assembly stage 2 – Housing
• Carefully remove the two O-rings (16) from the ring grooves in the housing
(1) with a screwdriver. If the O-rings are to be re-used, make sure that they
are in sound condition.
• Remove the four housing pins (15) from the relevant holes on the front of
the housing (1).
Housing dismantled

11/2008
5.2.7 Dismantling assembly stage 1 – Bearing flange, closed
• Remove the plain bearing bush (10) from the closed bearing flange (2).
• Remove the locking pin (11) from the groove.
Bearing flange, closed dismantled

11/2008
6 Tasks
Tasks / Exercises Table of contents
Worksheet 1 Introduction to the gear pump
Worksheet 2 Design, function and applications
Worksheet 3 Identifying causes of faults
Worksheet 4 Sealing systems
Worksheet 5 Inspection
Worksheet 6 Servicing
Worksheet 7 Repairs
Worksheet 8 Wearing parts
Worksheet 9 Assembling the gear pump
Worksheet 10 Changing the floating ring seal
Worksheet 11 Parts identification using the parts drawing
Worksheet 12 Spare parts ordering
6 Tasks 78
11/2008
Spare parts drawing and spare parts list

Spare parts drawing
6 Tasks 79
11/2008

Standard

6 Tasks 80
11/2008
6.1 Worksheet 1, page 1: Introduction to the gear pump
Objective:
To obtain an overview of the design and function of the gear pump.
Exercise:
You are provided with an assembled pump. Dismantle the pump so that all
the component parts are laid out before you.
Pump, fully assembled
Pump housing, dismantled
Take the pump drawings and the associated parts list. Locate the actual
components in the drawing.
Refer to the parts list to identify the correct names of the components.
6 Tasks 81
11/2008
Worksheet 1, page 2
You are now familiar enough with the overall design of the pump to be able
to answer the following questions:
1. How is the lead-through of the free end of the shaft sealed on this pump?
2. Does a gear pump have a specific direction of rotation? Or are clockwise

and anti-clockwise both possible?
3. Can you explain the basic operating principle of a gear pump?
4. Looking at the materials used – whose correct standard designations you

are familiar with from the parts list – which media could the pump be
suitable for?
6 Tasks 82
11/2008
6.2 Worksheet 2, page 1: Design, function and applications of gear pump
Objective:
To explain the design of the pump. To understand and describe its method of
operation and usage.
Exercise:
1. Describe the design of the pump.
Use the drawings.
2. Name the five key components.
3. Explain the method of operation of the pump. Explain the delivery

principle.
6 Tasks 83
11/2008
Worksheet 2, page 2
4. In what areas is the gear pump used?

6 Tasks 84
11/2008
6.3 Worksheet 3, page 1: Identifying causes of faults
Objective:
To identify or suspect likely causes of faults in response to specific
malfunctions while the pump is operating.
Exercise:
Try to find the causes of the faults listed in the table below. Note down your
assumptions in the right-hand section of the table.
You can exclude system-related disturbances.
Fault Suspected cause
Medium leaking at end of shaft
Running noise has markedly increased
The pressure difference usually generated

between the inlet and outlet is no longer
being attained. The pressure difference is
much less than normal
The pump housing has a much higher

surface temperature than normal
The current consumption of the drive motor

has increased significantly compared to
normal operating conditions
Media is escaping between the housing and

a bearing flange
6 Tasks 85
11/2008
6.4 Worksheet 4, page 1: Sealing systems
Objective:
To divide sealing systems into basic categories and identify them based on
the example of the gear pump.
Information on classification of sealing systems
Sealing systems
Static seals Dynamic seals

(seals subject to stationary (seals subject to motion)

stress)
Exercise:
1. Here you see the sectional drawing of the pump.
In the sectional drawing, mark the static seals as S and the dynamic seals
as D.
What respective functions do they perform?
Sectional drawing of pump
6 Tasks 86
11/2008
Worksheet 4, page 2
Once you have identified the sealing systems used in the gear pump, move
on to the following exercise.
2. Describe the design and method of operation of a shaft seal based on the
floating ring principle.
3. The drawing below represents a shaft seal based on the packing gland
principle. Describe the design and function of this shaft seal.
6 Tasks 87
11/2008
6.5 Worksheet 5, page 1: Inspection of pumps
Objective:
To know what the term “inspection” involves, and to draw up an inspection
plan.
Exercise:
1. What does the term “inspection” mean in the context of technical
maintenance?
Mark the statements you consider to be true or false in the Yes or No

column of the following table as appropriate.
Activity Yes No
The object of servicing is to record and assess the current actual status of a
pump
Components such as impellers or seals are replaced as a preventive

measure
Shaft bearings are lubricated and couplings re-aligned
Entire pump units are replaced
An inspection is always carried out with the system stopped
During an inspection, operating data for the pump system is measured (read)
and entered in an inspection plan
An inspection can be seen as equivalent to preventive repair
Inspection is a routine operation in machinery and plant maintenance X
6 Tasks 88
11/2008
Worksheet 5, page 2
When you have established what the term “inspection” means, move on to
the following exercise.
2. Imagine you are discussing a large gear pump which is of crucial
importance to the operation of a refinery.
Let us also assume that this large pump is similar in design to the small
pump from our MT 186 exercise project.
Draw up an inspection plan to be used to document/log an inspection
carried out.
Inspection plan/log
Pump: Inspected by:

Serial no.: Date:
Item Comments
6 Tasks 89
11/2008
6.6 Worksheet 6, page 1: Servicing pumps
Objective:
To know what is meant by the term “servicing”.
Exercise:
1. What does the term “servicing” mean in the context of technical
maintenance?
Activity Yes No
Components such as impellers, shaft seals and other seals are replaced as
a preventive measure
The object of servicing is to record and assess the current actual status of a
pump
Servicing of a pump is a routine operation, carried out at predefined intervals
A service is usually carried out with the system stopped
Servicing can be seen as equivalent to preventive repair
Activities during a service could include repositioning packing glands,

adjusting couplings or changing oil fillings
Servicing is always carried out when damage to a pump is identified
6 Tasks 90
11/2008
Worksheet 6, page 2
When you have established what the term “service” means, move on to the
following exercise.
2. Do you think that routine servicing is useful and necessary for the gear
pump from our MT 186 kit?
Give reasons for your decision.
3. Let us assume that two gear pumps with the conventional differing shaft
seals are being used in a chemical process. What servicing operations
need to be carried out on the packing gland type shaft seal and on the
floating ring seal?
6 Tasks 91
11/2008
6.7 Worksheet 7, page 1: Repair of pumps
Objective:
To know what is meant by the term “repairs” in this context and to draw up a
preventive maintenance plan.
Exercise:
1. What does the term “repairs” mean in the context of technical
maintenance? Mark the statements you consider to be true or false in the
Yes or No column of the following table as appropriate.
Activity Yes No
Repair involves replacing well-used parts with new ones: e.g. impellers,
seals
Repairs are carried out when damage has occurred to the pump
Repairs may also be carried out as routine and preventive measures to

prevent damage and stoppages from occurring in the first place
As part of preventive maintenance, repair measures prevent a pump from

failing before damage actually occurs
Repairs are normally carried out with the system stopped
If servicing is carried out on a regular basis, repairs are not needed
6 Tasks 92
11/2008
Worksheet 7, page 2
Once you have established what the term “repairs” means, move on to the
following exercise.
2. Let us assume that our gear pump is a key component in a chemical
process, where a failure of the pump would shut down the entire system.
In view of this, the pump is inspected and serviced at regular intervals.
To achieve an absolutely reliable operating condition, the plant
management decides to carry out routine preventive repairs on the unit.
Draw up a repair plan / order to be used as a basis for carrying out and
documenting the work.

Use the drawings.
Repair plan/order
Pump: Inspected by:

Serial no.: Date:
Procedure Comments/Status
Parts to be replaced:
Parts to be checked:
6 Tasks 93
11/2008
6.8 Worksheet 8, page 1: Wearing parts on gear pump
Objective:
To identify the wearing parts on the gear pump.
Exercise:
1. Mark the wearing parts on the pump drawing and name them.
2. Of what material are the wearing parts of the gear pump made? Enter the
wearing parts you have identified in the table along with the relevant
material.
Wearing part Material
6 Tasks 94
11/2008
6.9 Worksheet 9, page 1: Assembling the gear pump
Objective:
To structure the assembly process. To identify which assembly units can be
put together before overall assembly is carried out.
Exercise:
You have laid out all the component parts of the gear pump in front of you.
Your task is to assemble the gear pump.
First of all, individual assembly units are pre-assembled, and are then
combined to create the overall system.
1. Collect the components to be used to create an assembly unit. Give the
assembly unit a name.
Use the drawings.
6 Tasks 95
11/2008
Worksheet 9, page 2
•
Item Name
Item Name
Item Name
Item Name
Item Name
6 Tasks 96
11/2008
Worksheet 9, page 3
2. Once you have put together the various assembly units, the next step is to
assemble the body of the pump.
In doing this, set out the procedure in a structure as shown in the
schematic diagram.
Assembly of the floating ring seal should not yet be documented.
Assembly unit 2
(Housing)
Parts x, y, ...
Parts x, y, ...
Pump housing
6 Tasks 97
11/2008
Worksheet 9, page 4
Procedure for assembling the pump housing
Assembly unit 2
(Housing)
Pump housing
6 Tasks 98
11/2008
6.10 Worksheet 10, page 1: Changing the floating ring seal
Objective:
Planning and carrying out a change of floating ring seal on the gear pump.
Exercise:
1. Your task is to change the floating ring seal on the gear pump.
Set out your planned method in the pre-compiled work plan. Use the
drawings.
6 Tasks 99
11/2008
Worksheet 10, page 2

Work plan for gear pump floating ring seal change
Job no.: Carried out by:

Date: Date:
Estimated time required: __ min
No. Operation: Tools

6 Tasks 100
11/2008
6.11 Worksheet 11, page 1: Part identification using spare parts drawing,
familiarity with technical terms
Objective:
To assign items from a spare parts list to a spare parts drawing.
Exercise:
You will be given a spare parts drawing without item numbers.
Refer to the supplied spare parts list. Enter the item numbers specified in the
first column in the relevant fields on the spare parts drawing.

Standard
Spare parts list
6 Tasks 101
11/2008

Spare parts drawing
6 Tasks 102
11/2008
6.12 Worksheet 12, page 1: Spare parts ordering
Objective:
Identifying technical data for clear spare parts ordering.
Exercise:
You are going to carry out a repair, and need spare parts for your gear pump.
Select three parts you suspect are worn. Note the technical information for
these three parts that is necessary for a clear spare parts order.
Use the documents provided.
Spare parts order for pump:
Spare part:
6 Tasks 103
11/2008
7 Solutions
Tasks / Exercises Table of contents
Worksheet 1 Introduction to the gear pump
Worksheet 2 Design, function and applications
Worksheet 3 Identifying causes of faults
Worksheet 4 Sealing systems
Worksheet 5 Inspection
Worksheet 6 Servicing
Worksheet 7 Repairs
Worksheet 8 Wearing parts
Worksheet 9 Assembling the gear pump
Worksheet 10 Changing the floating ring seal
Worksheet 11 Parts identification using the parts drawing
Worksheet 12 Spare parts ordering
7 Solutions 104
11/2008
Spare parts drawing and spare parts list

Spare parts drawing
7 Solutions 105
11/2008

Standard

7 Solutions 106
11/2008
7.1 Worksheet 1, page 1: Introduction to the gear pump
Objective:
To obtain an overview of the design and function of the gear pump.
Exercise:
You are provided with an assembled pump. Dismantle the pump so that all
the component parts are laid out before you.
Pump, fully assembled
Pump housing, dismantled
Take the pump drawings and the associated parts list. Locate the actual
components in the drawing.
Refer to the parts list to identify the correct names of the components.
7 Solutions 107
11/2008
Worksheet 1, page 2
You are now familiar enough with the overall design of the pump to be able
to answer the following questions:
1. How is the lead-through of the free end of the shaft sealed on this pump?
With a floating ring seal.
2. Does a gear pump have a specific direction of rotation? Or are clockwise

and anti-clockwise both possible?
The direction of rotation on a gear pump is reversible, i.e. it operates with

both clockwise and anticlockwise rotation, although the conveying
direction is also reversed.
3. Can you explain the basic operating principle of a gear pump?

The liquid is pumped along the pump wall by the rotating gear wheels from
the intake to the delivery side in the gaps between the teeth.
4. Looking at the materials used – whose correct standard designations you

are familiar with from the parts list – which media could the pump be
suitable for?
The PTFE and stainless steel materials used in the construction of the
pump presented here are resistant to most aggressive chemicals.
7 Solutions 108
11/2008
7.2 Worksheet 2, page 1: Design, function and applications of gear pump
Objective:
To explain the design of the pump. To understand and describe its method of
operation and usage.
Exercise:
1. Describe the design of the pump.
Use the drawings.
The shafts have a floating design in PTFE plain bearing bushes using wear
discs.
The gear wheels are fixed to the shafts with a feather key and snap ring.
The two bearing flanges are secured to the housing with through bolts.
O-rings are used to seal the housing.
The shaft seal takes the form of a floating ring seal.
2. Name the five key components.

Bearing flange (closed and shaft), housing, shafts (driven and drive shaft),
gear wheels (driving and driven), floating ring seal
3. Explain the method of operation of the pump. Explain the delivery

principle.
Gear pumps work on the positive displacement principle. They are classed
as rotating positive displacement pumps.
The gear pump is powered by the drive shaft located below it. The PTFE
gear wheel located above is carried along by the lower stainless steel gear
wheel.
The rotating gear wheels convey the pumped liquid in a circumferential
direction along the surrounding housing, from the intake to the delivery
side.
Working valves are not required. The intake and delivery sides are
separated by a sealing gap.
7 Solutions 109
11/2008
Worksheet 2, page 2
4. In what areas is the gear pump used?

Gear pumps can generate operating pressures of up to 40 bar and delivery
flows of up to 60 m3/h.
They can pump high-viscosity media (oils, paints, adhesives, etc.).
The materials used in the construction of the pump presented here make
it resistant to most corrosive and aggressive chemicals.
7 Solutions 110
11/2008
7.3 Worksheet 3, page 1: Identifying causes of faults
Objective:
To identify or suspect likely causes of faults in response to specific
malfunctions while the pump is operating.
Exercise:
Try to find the causes of the faults listed in the table below. Note down your
assumptions in the right-hand section of the table.
You can exclude system-related disturbances.
Fault Suspected cause
Medium leaking at end of shaft Shaft seal defective
Running noise has markedly increased Bearing bushes damaged,

Shafts or gear wheels deformed,
Foreign bodies in the pump
The pressure difference usually generated Speed has decreased,

between the inlet and outlet is no longer Reverse flow in the pump has increased
being attained. The pressure difference is due to wear on the wear discs or gear
much wheels
less than normal
The pump housing has a much higher Shafts and gear wheels are scraping on the
surface temperature than normal housing due to severe wear or deformation
The current consumption of the drive motor Motor is defective,

has increased significantly compared to Speed has increased,
normal operating conditions
Foreign bodies in the pump and internal
parts scraping
Media is escaping between the housing and Housing seal defective

a bearing flange
7 Solutions 111
11/2008
7.4 Worksheet 4, page 1: Sealing systems
Objective:
To divide sealing systems into basic categories and identify them based on
the example of the gear pump.
Information on classification of sealing systems
Sealing systems
Static seals Dynamic seals

(seals subject to stationary (seals subject to motion)

stress)
Exercise:
1. Here you see the sectional drawing of the pump.
In the sectional drawing, mark the static seals as S and the dynamic seals
as D.
What respective functions do they perform?
The static seals seal the housing.
The dynamic seals seal the shaft feed-through.
D S D
7 Solutions 112
11/2008
Worksheet 4, page 2
Once you have identified the sealing systems used in the gear pump, move
on to the following exercise.
2. Describe the design and method of operation of a shaft seal based on the
floating ring principle.
Floating ring seals are contact seals which create a yielding seal
connection between stationary and rotating contact surfaces. Between the
contact surfaces is a film of liquid, which assumes a stable position due to
the centrifugal force occurring during rotation. The floating ring seal is
sealed against the housing using static elastomer seals. The floating ring
rotating with the shaft is held axially in place relative to the counter ring
fixed in the housing by a spring.
3. The drawing below represents a shaft seal based on the packing gland
principle. Describe the design and function of this shaft seal.
Packing glands are used to seal the pump shaft.

The gland packing is a woven cord mainly made of solid fabrics. It is
deformed in the packing space between the shaft and the housing by an
axial force and so pressed onto the surfaces being sealed.
A sleeve is fitted to protect the shaft. Locking rings or ancillary glands hold
the packing in place. The gland press compresses the packing using
screw fittings.
7 Solutions 113
11/2008
7.5 Worksheet 5, page 1: Inspection of pumps
Objective:
To know what the term “inspection” involves, and to draw up an inspection
plan.
Exercise:
1. What does the term “inspection” mean in the context of technical
maintenance?

Activity Yes No
The object of servicing is to record and assess the current actual status of a X
pump
Components such as impellers or seals are replaced as a preventive X

measure
Shaft bearings are lubricated and couplings re-aligned X
Entire pump units are replaced X
An inspection is always carried out with the system stopped X
During an inspection, operating data for the pump system is measured (read) X
and entered in an inspection plan
An inspection can be seen as equivalent to preventive repair X
Inspection is a routine operation in machinery and plant maintenance X
7 Solutions 114
11/2008
Worksheet 5, page 2
When you have established what the term “inspection” means, move on to
the following exercise.
2. Imagine you are discussing a large gear pump which is of crucial
importance to the operation of a refinery.
Let us also assume that this large pump is similar in design to the small
pump from our MT 186 exercise project.
Draw up an inspection plan to be used to document/log an inspection
carried out.
Inspection plan/log
Pump: Inspected by:

Serial no.: Date:
Item Comments
Pump capacity
Delivery pressure
Leakage
Noise
Smooth running
Temperature
General condition
7 Solutions 115
11/2008
7.6 Worksheet 6, page 1: Servicing pumps
Objective:
To know what is meant by the term “servicing”.
Exercise:
1. What does the term “servicing” mean in the context of technical
maintenance?
Activity Yes No
Components such as impellers, shaft seals and other seals are replaced as X
a preventive measure
The object of servicing is to record and assess the current actual status of a X
pump
Servicing of a pump is a routine operation, carried out at predefined intervals X
A service is usually carried out with the system stopped X
Servicing can be seen as equivalent to preventive repair X
Activities during a service could include repositioning packing glands, X

adjusting couplings or changing oil fillings
Servicing is always carried out when damage to a pump is identified X
7 Solutions 116
11/2008
Worksheet 6, page 2
When you have established what the term “service” means, move on to the
following exercise.
2. Do you think that routine servicing is useful and necessary for the gear
pump from our MT 186 kit?
Give reasons for your decision.
Yes! Servicing checks the condition of the wearing parts. On the gear
pump from the MT 186 these are the floating ring seal, the housing seals,
the bearing bushes and the wear discs. Damaged wearing parts are
replaced.
3. Let us assume that two gear pumps with the conventional differing shaft
seals are being used in a chemical process. What servicing operations
need to be carried out on the packing gland type shaft seal and on the
floating ring seal?
Packing glands must be repositioned depending on the leakage rate. Their
general condition must be checked and they must be repacked as
necessary.
Floating ring seals do not have to be adjusted. However, their condition
must be checked at each service. Preventive replacement of the floating
ring seal is advisable if very high reliability is required for operation of the
pump.
7 Solutions 117
11/2008
7.7 Worksheet 7, page 1: Repair of pumps
Objective:
To know what is meant by the term “repairs” in this context and to draw up a
preventive maintenance plan.
Exercise:
1. What does the term “repairs” mean in the context of technical
maintenance? Mark the statements you consider to be true or false in the
Yes or No column of the following table as appropriate.
Activity Yes No
Repair involves replacing well-used parts with new ones: e.g. impellers, X
seals
Repairs are carried out when damage has occurred to the pump X
Repairs may also be carried out as routine and preventive measures to X

prevent damage and stoppages from occurring in the first place
As part of preventive maintenance, repair measures prevent a pump from X

failing before damage actually occurs
Repairs are normally carried out with the system stopped X
If servicing is carried out on a regular basis, repairs are not needed X
7 Solutions 118
11/2008
Worksheet 7, page 2
Once you have established what the term “repairs” means, move on to the
following exercise.
2. Let us assume that our gear pump is a key component in a chemical
process, where a failure of the pump would shut down the entire system.
In view of this, the pump is inspected and serviced at regular intervals.
To achieve an absolutely reliable operating condition, the plant
management decides to carry out routine preventive repairs on the unit.
Draw up a repair plan / order to be used as a basis for carrying out and
documenting the work.

Use the drawings.
Repair plan/order
Pump: Inspected by:

Serial no.: Date:
Procedure Comments/Status
Parts to be replaced:
Floating ring seal (18)
Solid ring (12)
Housing seal (14)
Wear discs (13)
Plain bearing bush (10)
Locking pin (11)
Driven gear (9)
O-ring (16)
Parts to be checked:
Housing components
Driving gear
Shafts
7 Solutions 119
11/2008
7.8 Worksheet 8, page 1: Wearing parts on gear pump
Objective:
To identify the wearing parts on the gear pump.
Exercise:
1. Mark the wearing parts on the pump drawing and name them.
O-rings Floating ring seal

Housing seal
Wear disc Bearing bush Solid ring

2. Of what material are the wearing parts of the gear pump made? Enter the
wearing parts you have identified in the table along with the relevant
material.
Wearing part Material
Floating ring seal PTFE
Solid ring Ceramic
Housing seal PTFE
Bearing bush PTFE
O-ring PTFE
Wear discs PTFE
7 Solutions 120
11/2008
7.9 Worksheet 9, page 1: Assembling the gear pump
Objective:
To structure the assembly process. To identify which assembly units can be
put together before overall assembly is carried out.
Exercise:
You have laid out all the component parts of the gear pump in front of you.
Your task is to assemble the gear pump.
First of all, individual assembly units are pre-assembled, and are then
combined to create the overall system.
1. Collect the components to be used to create an assembly unit. Give the
assembly unit a name.
Use the drawings.
7 Solutions 121
11/2008
Worksheet 9, page 2
• Assembly unit 1 – Bearing flange, closed
Item Name
2 Bearing flange, closed
11 Locking pin
• Assembly unit 2 – Housing

Item Name
1 Housing
16 O-ring
15 Housing pin
• Assembly unit 3 – Bearing flange, shaft

Item Name
3 Bearing flange, shaft
11 Locking pin
• Assembly unit 4 – Driven shaft

Item Name
6 Driven shaft
17 Feather key
9 Driven gear
23 Snap ring
• Assembly unit 5 – Drive shaft

Item Name
5 Drive shaft
17 Feather key
8 Driving gear
23 Snap ring
7 Solutions 122
11/2008
Worksheet 9, page 3
2. Once you have put together the various assembly units, the next step is to
assemble the body of the pump.
In doing this, set out the procedure in a structure as shown in the
schematic diagram.
Assembly of the floating ring seal should not yet be documented.
Assembly unit 2
(Housing)
Parts x, y, ...
Parts x, y, ...
Pump housing
7 Solutions 123
11/2008
Worksheet 9, page 4
Procedure for assembling the pump housing
Assembly unit 2
(Housing)
Assembly unit 5
(Drive shaft)
Assembly unit 4
(Driven shaft)
Wear disc
(13)
Assembly unit 1
(Bearing flange,
closed)
Assembly unit 3
(Bearing flange,
shaft)
Hexagon
screw fitting
(20, 21, 22)
Pump housing
7 Solutions 124
11/2008
7.10 Worksheet 10, page 1: Changing the floating ring seal
Objective:
Planning and carrying out a change of floating ring seal on the gear pump.
Exercise:
1. Your task is to change the floating ring seal on the gear pump.
Set out your planned method in the pre-compiled work plan. Use the
drawings.
7 Solutions 125
11/2008

Work plan for gear pump floating ring seal change
Job no.: Carried out by:

Date: Date:
Estimated time required: 45 min
No. Operation: Tools
Dismantling
1 Loosen hexagon screws (19) and spring washer (22) and uniformly screw out of Combination
shaft bearing flange (3). wrench 11
2 Remove seat ring (4) from drive shaft (5) and solid ring (12).
3 Remove solid ring (12) with housing seal (14) from drive shaft (5).
4 Remove housing seal (14) from solid rind and bearing flange.
5 Loosen screw plugs (7) and twist out of threaded hole on shaft bearing flange. Combination
wrench 11
6 Turn shaft manually until the hexagon screws for the floating ring seal (18) are Hexagon
visible through the threaded hole for the screw plug (7). Loosen all four screws. socket wrench
7 Carefully slide floating ring seal out of bearing flange with a slotted screwdriver Slotted
through screw plug hole. Remove the floating ring seal from the shaft. screwdriver
Assembly
8 Slide the floating ring seal (18) over the shaft into the shaft bearing flange (3) until
the hexagon screw is visible through the threaded hole for the screw plug (7).
9 Tighten the screw with the hexagon socket wrench. Turn the shaft manually until Hexagon
the other hexagon screws are visible. Tighten to fasten the floating ring seal on socket wrench
the shaft.
10 Slide a housing seal (14) onto each side of the solid ring (12).
11 Slide the solid ring (12) over the shaft against the shaft bearing flange (3).
12 Slide the seat ring (4) over the shaft and solid ring (12) against the bearing flange
(3).
13 Screw the seat ring against the bearing flange with hexagon screws (19) and Combination
spring washer (22). Tighten the screws uniformly. wrench 11
14 Wind two to three layers of Teflon tape around the thread of the screw plugs (7). Teflon tape
15 Twist the screw plugs (7) into the threaded hole on the shaft bearing flange and Combination
tighten lightly. wrench 11
7 Solutions 126
11/2008
7.11 Worksheet 11, page 1: Part identification using spare parts drawing,
familiarity with technical terms
Objective:
To assign items from a spare parts list to a spare parts drawing.
Exercise:
You will be given a spare parts drawing without item numbers.
Refer to the supplied spare parts list. Enter the item numbers specified in the
first column in the relevant fields on the spare parts drawing.

Standard
Spare parts list
7 Solutions 127
11/2008
12
18
13
10
16
17
9
23
6
Spare parts drawing
7 Solutions 128
11/2008
7.12 Worksheet 12, page 1: Spare parts ordering
Objective:
Identifying technical data for clear spare parts ordering.
Exercise:
You are going to carry out a repair, and need spare parts for your gear pump.
Select three parts you suspect are worn. Note the technical information for
these three parts that is necessary for a clear spare parts order.
Use the documents provided.
Spare parts order for pump:

Type: Liquiflo
Serial no.: 35155-1-2
Spare part:
1 x Floating ring seal Item 18
1 x Solid ring Item 12
2 x Housing seal Item 14
7 Solutions 129
11/2008
8 Index
A
Assembly stage 1 – Bearing flange, closed . . . . . . . . . . . . . . . . . . 53, 77
Assembly stage 2 – Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 76
Assembly stage 3 – Bearing flange, shaft . . . . . . . . . . . . . . . . . . . . 57, 76
Assembly stage 4 – Driven shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 75
Assembly stage 5 – Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61, 75
Assembly stage 6 – Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 74
Assembly stage 7 – Floating ring seal . . . . . . . . . . . . . . . . . . . . . . 68, 73
C
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 8, 29
Centrifugal pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29
Characteristic curve, pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Characteristic curve, system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
D
Diaphragm pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 11, 30
Dynamic seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F
Floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 48
G
Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14, 32, 46, 52
Gear pump dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Gear pump spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Gear pump spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Gear pump technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
H
Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 Index 130
11/2008
I
Inline centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 13, 31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Intake characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Multi-flow pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Multiple-stage pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Multi-stage centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29
O
Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
P
Packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Parallel configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 12, 31
Piston rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 41
Piston seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Positive-displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14
Pump characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pump, multi-flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
R
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 34
Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
S
Screw pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 10, 30
Seals, dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Seals, floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 48
Seals, packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Seals, static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Series configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Standard centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 Index 131
11/2008
Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
System characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
V
Valves in pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 Index 132
11/2008
9 Drawings
Name Drawing number
Assembly drawing MT186.00.01.000
Parts list MT186.00.01.000S
Housing MT186.10.01.001
Bearing flange, closed MT186.10.01.002
Bearing flange, shaft MT186.10.01.003
Seat ring MT186.10.01.004

Drive shaft MT186.10.01.005
Driven shaft MT186.10.01.006
Screw plug MT186.10.01.007
Driving gear MT186.10.01.008
Driven gear MT186.10.01.009
Plain bearing bush MT186.10.01.010
Locking pin MT186.10.01.011
Solid ring MT186.10.01.012
Wear disc MT186.10.01.013
Housing seal MT186.10.01.014
Housing pin MT186.10.01.015
9 Drawings 133

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Teaching material

MT 186 Assembly and Maintenance

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

Dipl.-Ing. Klaus-Jürgen Radtke

Version 1.2 Subject to technical alternations

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

2 Technological principles of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.4 Operating characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 Basics of pump maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

4 Technical description Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5 Assembly and dismantling Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.1 Gear pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

6.7 Worksheet 7, page 1: Repair of pumps . . . . . . . . . . . . . . . . . . . . . . . 92

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

7.11 Worksheet 11, page 1: Part identification using spare parts

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

MT 180 Assembly and maintenance exercise - centrifugal pump

MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump

MT 182 Assembly and maintenance exercise - screw pump

MT 183 Assembly and maintenance exercise - diaphragm pump

MT 184 Assembly and maintenance exercise - piston pump

MT 185 Assembly and maintenance exercise - in-line centrifugal pump

MT 186 Assembly and maintenance exercise - gear pump

Tab. 1.1 Product relating to pump assembly and maintenance

This kit includes a gear pump.

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

The following learning content is covered:

Learning content / Exercises

Design and function of a gear pump

Assembly and disassembly, including for maintenance purposes

Replacing components (e.g. seals)

Reading and understanding engineering drawings and operating instructions

Comparing different pumps

Tab. 1.2 Learning content / Exercises

The teaching material includes a technical description detailing the basics of

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

2 Technological principles of pumps

MT 180 Assembly and maintenance exercise - centrifugal pump

MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump

MT 182 Assembly and maintenance exercise - screw pump

MT 183 Assembly and maintenance exercise - diaphragm pump

MT 184 Assembly and maintenance exercise - piston pump

MT 185 Assembly and maintenance exercise - in-line centrifugal pump

MT 186 Assembly and maintenance exercise - gear pump

Wherever liquids are transported, produced or required to be supplied,

2 Technological principles of pumps 3

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

2.1 Classification and categorisation of pump types based on operating

Positive-displacement Centrifugal pumps

Oscillating Rotating Normally priming Self-priming

Piston pumps Gear pumps Centrifugal pumps Side-channel

Fig. 2.1 Pump types

2 Technological principles of pumps 4

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP

2.2 Designs and operating characteristics

The piston pump incorporates an oscillating piston

stroke the pump chamber is reduced and the pumped

The diaphragm pump contains an elastomer

The gear pump contains two opposite rotating rigid or

The screw pump consists of two or more spindles with

2 Technological principles of pumps 5

MT 186 ASSEMBLY AND MAINTENANCE EXERCISE: GEAR PUMP