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402 – 17.02.EN
ATEX
Inch Units
These operating instructions contain fundamental information and precautionary notes. Please read the manual
thoroughly prior to installation of unit, electrical connection and commissioning. It is imperative to comply with all
other operating instructions referring to components of individual units.
This manual shall always be kept close to the unit’s location of operation or directly on the pump set.
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EC Declaration of Conformity
PART NUMBER:
SERIAL NUMBER:
DATE MANUFACTURED:
Machinery: The designated product complies with the following basic requirements of Directive 2006/42/EC:
Appendix I, section 1.1.2, 1.1.3., 1.1.5., 1.3.1., 1.3.2., 1.3.3., 1.3.4., 1.3.7., 1.3.8., 1.4.1., 1.4.2.1.,
1.5.1., 1.5.8., 1.5.9., 1.5.13., 1.6.1., 1.6.4., 1.6.5., 1.7.
ATEX: 94/9/EC
NOTIFIED BODY
Det Norske Veritas, ATEX NB 0575 retains a copy of the Technical File
The product described in this Declaration of Conformity complies with the Applicable European Directives and
relevant sections of the Applicable International Standards. The signature on this document authorizes the
distinctive European mark to be applied to the equipment described. A Technical Construction File is available for
inspection by designated bodies
Important safety information is contained in the installation, operation and service manuals; read and
understand this information prior to installing or using this equipment
This Document applies only to the equipment described above and is invalid if not reproduced in its
entirety.
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PUMP RATING
Service ______________________________________
PUMP MATERIALS
MOTOR DATA
TABLE OF CONTENTS
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Pump operation outside its specified operating range Based on an ambient temperature of 104˚ Fahrenheit
may also result in dry running. (F) [40˚ Celsius (C)] and proper maintenance and
operation, compliance with temperature class T4 is
warranted in the area of the rolling element ball
K.5 Temperature Limits.
bearings. A special design is required for compliance
with temperature class T6 in the ball bearing area. In
In normal pump operation, the highest such cases, and if ambient temperature exceeds 104˚F
temperatures are to be expected on the surface (40˚C), contact the manufacturer.
of the pump volute, at the shaft seal and in the
ball bearing areas. The surface temperature at
the pump volute corresponds to the
temperature of the fluid handled.
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K.6 Maintenance. Check to make sure that the frame of the driver
and starter panel are securely grounded before
operating pumping unit or performing any tests
Only a pumping unit which is properly or measurements.
serviced and maintained in perfect technical
condition will give safe and reliable operation. If a test meter must be held or adjusted while
voltage is applied, ground case of meter before
This also applies to the reliable function of the thrust and starting measurement. DO NOT touch live
radial ball bearings whose actual lifetime largely equipment while holding the meter. Some
depends on the operating mode and operating moving vane-type meters should not be
conditions. Regular checks of the lubricant and the grounded nor held during measurements.
running noises will prevent the risk of excessive DO NOT use test equipment known to be
temperatures as a result of the thrust or radial ball damaged or in poor condition.
bearings running hot or defective bearing isolators.
The correct function of the bearing isolators must be The following specific safety precautions apply to the
checked regularly. Any auxiliary systems installed must pumping unit:
be monitored, as necessary, to make sure that they
function correctly. DO NOT exceed maximum discharge pressure.
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volute/adaptor studs (631) and volute hex nuts (616) The first method involves the use of a sight glass
with volute/backhead lockwashers (655). constant level oiler (143). The sight glass maintains the
oil level high enough on the higher of the two bearings
Item 2 - Impeller. Maxum pumps are equipped with
so that the bearings themselves provide the motivation
enclosed impellers, except the low-flow high-head
for the oil to be moved through the races of the
Maxum pumps that are equipped with open impellers.
bearings.
The impeller (2) is keyed to the shaft (6) by the impeller
key (32) and is locked in place by the impeller nut or A second method is to provide an oil flinger (60) which
optional inducer (24) and impeller washer (28). mounts on the shaft (6) and literally flings the oil
throughout the bearing frame. An oil view gauge
Item 6 - Shaft. The shaft (6) of the Maxum pump is
indicator (143) is usually used with this system to make
designed for maximum deflection of 0.002 inch at the
sure that the oil level within the frame can be observed
face of the mechanical seal (90). The shaft is also
and maintained at the proper level.
designed to provide stabilization to the rotor system
when pump operates away from the best efficiency A third method is the oil mist system. All Maxum pumps
point. A coupling (42) connects the shaft to the driver are equipped so that they can be used or can be
shaft (190). The pump coupling key (46) holds the converted to oil mist units without any field machining-.
coupling in place, causing it to rotate with the shaft.
Item 11 - Backhead. The backhead (11) is fastened to Oil Mist system for ATEX applications
the volute (1) with volute/adaptor studs (631), volute hex require a user installed system of safety
nuts (616), and volute/backhead lockwashers (655). The controls or alarms to insure that the pump is
backhead houses backhead wear ring (7X). The shut down in event of an oil mist failure.
backhead is positioned in the volute bore by volute
gasket (73C*) or O-ring (89A*). In addition to the oil lube system, the bearing frame (19)
The bearing frame (19) is attached to the backhead with contains the bearing isolators (47 & 49). The Maxum
backhead stud (632), backhead hex nut (617) and pump bearing frame is equipped with a labyrinth oil seal
adaptor/frame lockwashers (656). assembly which becomes a static seal when stopped.
The backhead (11) contains forcing bolts (610) to aid in Item 23 - Base. A grout-able base (23) is designed to
loosening the backhead from the volute (1). provide adequate support for the pump and motor so
pump can be operated without base deflection,
Item 16 and 18 – Ball Bearings. A deep-groove excessive vibration, or resonance. The volute (1) is
Conrad-type, C3 internal fit radial ball bearing (16) and attached to the base with stud (634) and hex nut (614).
light preload, back-to-back mounted thrust ball bearings Grouting of this type of base is required by Carver Pump
(18) are housed in the bearing frame (19). The thrust Company.
ball bearings will be designated as 7000 or 8000 series.
Thrust ball bearings designated in the 7000 series will Item 90 – Mechanical Seal. Cartridge mechanical
be duplex 40° angular contact ball bearings. Thrust ball seals (90) are to be used. Complete cartridge
bearings designated in the 8000 series will have 40° mechanical seal instructions should be obtained from
and 15° angular contact. The thrust ball bearing is held the seal manufacturer. The standard seal chamber
in place by the bearing locknut (22) and bearing dimensions are shown in Figure 1.
lockwasher (69). The ball bearings are oil lubricated.
Either oil bath lubrication or an oil mist system may be
employed.
Item 19 - Bearing Frame. The principal function of the
bearing frame (19) is to carry the loads from the liquid
end of the pump to the base and to transport power from
the power unit to the impeller (2). The bearing frame has
a radial ball bearing (16) located in the front end of the
bearing frame (nearest to the volute) and a pair of
back-to-back mounted angular contact thrust ball
bearings (18) in the rear of the bearing frame. This
bearing frame is designed to be oil lubricated, which can
be accomplished in several ways.
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Motor 3550 RPM 2950 RPM 1750 RPM 1450 RPM 1150 RPM
Pump Pump Pump Pump Pump
Pump Pump Pump Pump Pump
and and and and and
HP kW Only Only Only Only Only
Motor Motor Motor Motor Motor
dB[A] dB[A] dB[A] dB[A] dB[A]
dB[A] dB[A] dB[A] dB[A] dB[A]
>5 >3.7 82 77 81 78 74 71 75 73 71 69
7.5 5.6 86 81 85 82 78 75 79 77 75 73
10 7.4 86 81 85 82 78 75 79 77 75 73
15 11.2 87 82 86 83 79 76 80 78 76 74
20 14.9 88 83 87 84 80 77 81 79 77 75
25 18.6 88 83 87 84 80 77 81 79 77 75
30 22.4 88 83 87 84 80 77 81 79 77 75
40 29.8 96 91 95 92 88 85 89 87 85 83
50 37.3 96 91 95 92 88 85 89 87 85 83
60 44.7 96 91 95 92 88 85 89 87 85 83
75 55.9 96 91 95 92 88 85 89 87 85 83
100 74.6 96 91 95 92 88 85 89 87 85 83
125 93.2 96 91 95 92 88 85 89 87 85 83
150 111.9 96 91 95 92 88 85 89 87 85 83
The tolerance for these values is ±3 dB[A].
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X
Y
X
Z
Suction Discharge
Pump Size
Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz
AA- 1½ x 1 x 6 200 160 130 340 170 260 160 130 200 340 170 200
AB - 2 x 1½ x 6 200 160 130 340 170 260 160 130 200 340 170 200
AC- 3 x 1½ x 6 300 240 200 700 350 530 160 130 200 340 170 200
AD - 3 x 2 x 6 300 240 200 700 350 530 160 130 200 340 170 200
AE - 4 x 3 x 6 400 320 260 980 500 740 240 200 300 700 350 530
BA - 1½ x 1 x 8 200 160 130 340 170 260 160 130 200 340 170 200
BB - 2 x 1½ x 8 200 160 130 340 170 260 160 130 200 340 170 200
BC - 3 x 1½ x 8 300 240 200 700 350 530 160 130 200 340 170 200
BD - 3 x 2 x 8 300 240 200 700 350 530 160 130 200 340 170 200
BE – 4 x 3 x 8 400 320 260 980 500 740 240 200 300 700 350 530
BF - 6 x 4 x 8 700 560 460 1700 870 1,300 320 260 400 980 500 740
CA – 2 x 1½ x 10 200 160 130 340 170 260 160 130 200 340 170 200
CB - 3 x 1½ x 10 300 240 200 700 350 530 160 130 200 340 170 200
CC - 3 x 2 x 10 300 240 200 700 350 530 160 130 200 340 170 200
CD - 4 x 3 x 10 400 320 260 980 500 740 240 200 300 700 350 530
CE - 6 x 4 x 10 700 560 460 1700 870 1,300 320 260 400 980 500 740
CF - 6 x 6 x 10 700 560 460 1700 870 1,300 560 460 700 1700 870 1300
CG - 8 x 6 x 10 1100 850 700 2600 1,300 1,900 560 460 700 1700 870 1300
DA - 2 x 1½ x 13 200 160 130 340 170 260 160 130 200 340 170 200
DB - 3 x 2 x 13 300 240 200 700 350 530 160 130 200 340 170 200
DC - 4 x 3 x 13 400 320 260 980 500 740 240 200 300 700 350 530
DD - 6 x 4 x 13 700 560 460 1700 870 1,300 320 260 400 980 500 740
DE - 6 x 6 x 13 700 560 460 1700 870 1,300 560 460 700 1700 870 1300
DF - 8 x 6 x 13 1100 850 700 2600 1,300 1,900 560 460 700 1700 870 1300
DG - 10 x 8 x 13 1500 1200 1000 3700 1800 2800 850 700 1100 2600 1,300 1,900
DH – 12 x 10 x 13 1800 1500 1200 4500 2200 3400 1200 1000 1500 3700 1800 2800
ED- 6 x 4 x 16 700 560 460 1700 870 1,300 320 260 400 980 500 740
EA- 8 x 6 x 16 1100 850 700 2600 1,300 1,900 560 460 700 1700 870 1300
EB - 10 x 8 x 16 1500 1200 1000 3700 1800 2800 850 700 1100 2600 1,300 1,900
EE - 12 x 10 x 16 1800 1500 1200 4500 2200 3400 1200 1000 1500 3700 1800 2800
EC - 14 x 12 x 16 2000 1600 1300 4700 2300 6300 1,500 1200 1800 4500 2200 3400
FA - 8 x 6 x 20 1100 850 700 2600 1,300 1,900 560 460 700 1700 870 1300
FB - 10 x 8 x 20 1500 1200 1000 3700 1800 2,870 850 700 1100 2600 1,300 1,900
FC - 12 x 10 x 20 1800 1500 1200 4500 2200 3400 1200 1000 1500 3700 1800 2800
FD - 14 x 12 x 20 2000 1600 1300 4700 2300 6300 1,500 1200 1800 4500 2200 3400
M = Moments measured in Foot-Pounds (FT-lbs)
F = Forces measured in Pounds (lbs)
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VII. INSTALLATION.
A. LOCATION. The pump assembly should be
located in an area that will permit periodic inspection
Figure 2. Sling Position for Moving Pump
and maintenance. Head room and access should be
provided and all units should be installed in a dry
location with adequate drainage. The discharge piping
should be direct with as few elbows and fittings as
possible.
The pump assembly should be installed as close to the
fluid as possible. A short, direct suction pipe can be
used to keep suction losses at a minimum. If possible,
locate the pump so fluid will flow by gravity to the
suction opening. The discharge piping should be direct
with as few elbows and fittings as possible. The total Net
Positive Suction Head Available (NPSHA), which
includes the suction lift and pipe friction losses, must be Figure 3. Sling Position for Moving Pumping unit
greater than the Net Positive Suction Head Required
(NPSHR) by the pump. C. FOUNDATION. Make sure that the concrete
foundation has set firmly before placing the unit on it. Its
B. HANDLING. surface must be truly horizontal and even. The
foundation bolts must be inserted in the base holes. The
WARNING foundation should be 3 to 6 inches wider and longer
than the base, have a level surface, and be of sufficient
If the pumping unit slips out of the sling mass to prevent vibration and form a permanent rigid
arrangement, it may cause injury to personnel support for the unit. The best foundations are concrete
and/or damage to the pumping unit. with anchor bolts of adequate size embedded in the
foundation in pipe sleeves having an inside diameter 2-
1/2 times larger than the bolt diameter. This will allow for
CAUTION accurate positioning of the unit. Keep the concrete
surface clean, yet rough.
Use a hoist with adequate lifting capacity.
Hydraulic Institute (HI) recommends a foundation
capable of absorbing vibration at least five times the
Do not pick up the complete unit by the motor
weight of the pumping unit and to form a permanent,
or the pump shafts or motor lifting eyes.
rigid support for the base plate. Consequently,
maintaining the pump to driver alignment is important for
Moving the unit requires proper preparation and
a flexible coupled unit, refer to Figure 6. A concrete
handling. Always make sure that the pump or the
foundation on a solid base is recommended. Use
pumping unit remains in a horizontal position while
foundation bolts of the proper size embedded into the
being moved and cannot slip out of the transport
concrete. A pipe sleeve larger in diameter than the bolt
suspension arrangement. Use a sling for pumps without
should be used. This allows movement for final
baseplates, refer to Figure 2. To lift a horizontal
positioning of the bolts. Refer to Figure 4, Grouting and
mounted unit, a hoist or suitable lifting device should be
Foundation Bolting.
attached to each corner of base structure, refer to
Figure 3. The individual motor may be lifted using proper As soon as the pump and driver, mounted on a base, is
eyebolts provided by the manufacturer, but these should placed on the foundation, remove the coupling guard
not be used to lift the assembled unit. and disconnect coupling halves. The base should be
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supported by the provided jacking screws. Refer to 1. Wax forms heavily with at least three coats of
Figure 5; adjust the leveling screws until provided base paste wax. Forms must be substantial and well
Milled Leveling Pads are true in both the axial and braced. All corners, joints, bottoms must be
transverse directions. Verify that the pump and driver sealed with silicone caulk for water tightness. All
shafts are level. Check coupling faces, as well as, forms should have a 45° chamfer strip installed
suction and discharge flanges of the pump for horizontal to prevent stress risers.
or vertical positioning by means of a level. Make 2. Anchor bolt-free length must be wrapped with
corrections, as necessary, by adjusting the leveling duct seal or electricians plastic tape to prevent
screws on the base. grout from contacting the bare metal. Grout
D. LEVELING OF UNIT. When the pump is supplied sticking to the anchor bolt will prevent the
complete with motor and base, the unit is assembled at elongation necessary to develop the hold-down
the factory. Lower unit onto foundation, positioning base force. Failure to do this will result in broken
structure so anchor bolts are aligned in middle of holes anchor bolts.
in base. 3. Leveling screws must be greased to permit
removal prior to the final torque.
The base should be supported on either rectangular
metal blocks with shims or on metal wedges having a 4. Do not use shim packs as a leveling device
small taper. The support pieces should be placed close unless it is planned to remove them prior to final
to the foundation bolts. Refer to Figure 4, Grouting and torque application.
Foundation Bolting. Place supports directly under the 5. Leveling screw pads should be a minimum of
part of the base, which carries the greatest weight. 1/2" thick with minimum diameter of 3". Corners
Space the supports closely enough to provide uniform of pad must be rounded to approximately 1/8"
support of the base. Adjust the metal supports or radius to prevent stress cracking. Set leveling
wedges until the shaft is level. Check suction and screws on the chipped concrete surface. Set the
discharge flanges of the pump by means of a level. pad with quick set cement or Resin Repair
Make corrections, as necessary, by adjusting the Compound. With jacking bolt pads secure and
supports or wedges under the base. level, set and level base with leveling screws.
The base should be supported on metal shims or metal 6. The underside of the standard factory steel
wedges placed directly beneath the part of the base base plate was painted with epoxy grout primer
supporting the most weight. The shims or wedges and should only require proper cleaning. If the
should be spaced close enough to give support and base must be sandblasted, prepare the contact
stability. faces to SSPC-SP 6 Spec. If base cannot be set
within 24 hours of blasting, the underside must
Adjust metal supports or wedges until suction and be coated with a compatible Rust Inhibitive
discharge flanges are level. Primer. Tighten foundation bolts loosely. Allow
the grout to fully cure before firmly tightening the
CAUTION foundation bolts.
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*Lifting Eye
Milled Pads
*Drip Pan & Drain
*Leveling Bolt
*Not on all Bases
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F. COUPLING ALIGNMENT. The pump and motor shims under the feet or supports of the motor and
are connected by a coupling. The base aligns the pump tighten fastening bolts until correct alignment is
and motor. No further alignment is necessary unless the achieved.
pump or motor were removed from the base or if there
1. Move the pump or motor to achieve acceptable
was not a base purchased with the unit then the
alignment. When properly aligned, the disc
following is how to check the coupling alignment. The
packs will be centered and approximately
coupling should NOT be reconnected until the alignment
parallel to their mating flange faces and the
has been completed.
flexing elements will have little visible waviness
when viewed from the side.
NOTE
NOTE
Refer to coupling manufacturer’s manual for
instructions regarding shaft alignment and
Refer to the coupling manufacturer’s manual for
recommended installation limits.
recommended installation limits for Parallel,
Angular, and Axial alignment.
Soft Foot – The equipment must rest flat on its
base. If one or more feet of the pump or motor
2. The “Parallel Misalignment” value (P) is the
are shorter, longer, or angled in some way to
offset between the centers of the hubs, as
prevent uniform contact (a condition commonly
shown in Figure 6.
known as “soft foot”) it must now be corrected.
3. When the Parallel Offset is measured by
To improve the life of the coupling, the shafts must be rotating the hubs in unison with dial indicators
aligned to minimize deflection of the flexing elements. as shown in Figure 6, the Total Indicator
Shaft alignment is required in the axial, parallel, and Reading (TIR) should be divided by (2) to
angular directions, with each of these values not to calculate (P).
exceed the recommended installation limits. Shaft 4. It should be noted that parallel offset measured
alignment can be measured using various established on the hub surfaces includes misalignment of
methods, including Laser Alignment, Reverse Dial the equipment shafting plus any variation (TIR)
Indicator, and Rim and Face. in the hubs. This may be helpful to consider
during problem solving for alignment difficulties.
The motor and pump shafts must be accurately aligned
as any misalignment can cause damage to the coupling, 5. The “Angular Misalignment” value is the
motor, or pump. When the shafts are in correct maximum difference between the
alignment, the coupling hubs will be on a common axis, measurements X and Y taken at opposite ends
concentric with each other, and at the correct distance of the hub flanges, as shown in Figure 6.
apart. If the coupling hubs are misaligned, it is general
practice to adjust the driver to the pump. Insert full
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1. Before starting or operating the pump, read this B. PRIMING. Dry running a centrifugal pump can
entire manual, especially the following result in extensive damage and possible seizing. It is,
instructions. therefore, imperative that the pump be primed prior to
initial start-up and that prime must be maintained
2. Observe all caution or danger tags attached to
through subsequent start-stop cycles.
the equipment.
The priming procedure is different for positive and
CAUTION negative suction head systems. Follow the procedure
listed below.
Pumps are shipped without oil and should Positive Suction Head:
be filled with oil before starting the pumping
unit. Operation of the unit without proper 1. Open the vent on the highest point on the pump
lubrication can result in overheating of the ball volute.
bearings, ball bearing failures, pump seizures 2. Open all suction valves.
and actual breakup of the equipment, exposing
operating personnel to injury. 3. Allow liquid to flow from vent hole until all air
bubbles are vented. Then close the vent.
3. Fill bearing frame with oil (refer to Section X, 4. The pump is now primed.
Paragraph A and Table 7). Pumps are shipped
with no oil in the bearing frame. If ball bearings Negative Suction Head:
are oil mist lubricated, turn on system, wait for
proper oil quantity and check monitoring 1. Install an ejector or vacuum pump on the vent at
system. the highest point on the volute.
2. Close the discharge valve.
CAUTION 3. Open the suction valve.
4. Start the ejector or vacuum pump.
Never run the pump dry. Close running fits 5. Allow liquid to flow until a continuous flow is
within the pump are liquid lubricated. Dry exhausted from ejector. Then close the valve to
running will result in pump seizure or damage. the vent.
6. The pump is now primed.
4. Before starting the pump, fill the volute and
suction line with liquid. The pump may be
primed by using an ejector or vacuum pump.
5. Before starting a mechanical seal pump
equipped with external flush lines, turn on
mechanical seal water, and confirm the
mechanical seal water is at sufficient pressure.
Refer to Table 8 for minimum cooling flow rates.
6. Check final alignment of pump and driver. Both
shafts must turn freely by hand. If necessary,
check coupling alignment.
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CAUTION g*H
ΔT = *(1-η)
DO NOT operate pumping unit against a closed c*η
discharge system. If pump has any chance of
seeing operation against a closed system, a
c Specific heat [J / kg K]
bypass system allowing a minimum design flow
should be installed. This bypass will be g Acceleration due to gravity [m/s_]
satisfactory for short periods of operation. For H Pump head [m]
extended periods of operation the bypass
should be sized for the minimum continuous T f Temperature of fluid handled [°C]
flow required by the pump. Refer to Section T o Temperature of casing surface [°C]
VIII, Paragraph E for minimum/maximum flow
η Pump efficiency at duty point [-]
calculation.
Δ T Temperature difference [°C]
1. Confirm pumping unit is ready to start.
Complete Section VIII, Paragraphs A and B. F. OPERATING CHECKS.
2. If unit is equipped with mechanical seal cooling 1. Check for undue vibration or noise. If any
lines, turn on mechanical seal cooling water. occurs and does not stop within a short period
3. Fully open the suction valve. of time, turn off the pump. For determination of
4. Open discharge valves slightly, about 1 to 1 ½ the cause and its remedy refer to
turns if pump is being started for the first time or Troubleshooting in Section IX or consult Carver
from being turned off for overhaul. Start the Pump Company.
pump. 2. Check and record flow and pressure readings.
5. Slowly open discharge valves and adjust The flow and pressure readings should be
pressure and flow to the appropriate operating within the operating system guidelines and
conditions. Refer to pump nameplate and similar to number stamped on the pump
system operating procedures for design point nameplate.
condition. 3. Check and record ball bearing temperature
according to the following steps, if remote
D. TURBINE APPLICATIONS. For turbine thermal devise or equal is not installed. Ball
applications, consult your local distributor or a bearing temperature should not exceed 190° F
representative from Carver Pump Company. (87° C).
a. Remove plug (420) on bearing frame
E. MINIMUM/MAXIMUM FLOW CALCULATION. (19) race.
Unless otherwise specified in the characteristic curves
b. Measure and record ball bearing
or on the data sheets, the following applies
temperatures under where plug (420)
was located.
Qmin = 0.1 x Qopt for short operation
c. Reinstall plug (420) on bearing frame
Qmin = 0.3 x Qopt for continuous operation (19) race.
Qmax = 1.1 x Qopt for 2-pole operation 4. Check and record power input to the motor.
Qmax = 1.25 x Qopt for 4-pole operation 5. Check for leakage at mechanical seals.
Qopt = optimum efficiency
G. STOPPING THE PUMP.
The data above refers to water and water-like liquids.
However, if the physical properties of the fluids handled 1. If the pump is being stopped for overhaul, slowly
are different from water, the calculation formula below close the discharge valve. Otherwise leave
must be used to check if an additional heat build-up may discharge valves set at condition.
lead to a dangerous temperature increase at the pump 2. Stop the pumping unit in accordance with the
surface. If necessary, the minimum flow must be directions on the electrical power supply.
increased.
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vent (45). Fill bearing frame until oil can be seen in the ball bearings. The plug in the bottom of the power frame
center of the bullseye sight. should be removed so that condensed oil vapor can be
drained and/or removed from the bearing frame.
Table 7. Oil Recommendations
B. LUBRICATION OF MOTOR BALL BEARINGS.
Manufacturer ISO Grade 22, 32, 68 See motor manufacturer’s instructions to be sure motor
Royal Purple Synfilm ball bearings are properly lubricated.
Texaco Regal R&O
Phillips Magnus Oil C. TORQUE VALUES. Refer to Table 9,
Exxon Teresstic Recommended Torque Values. Clean and properly
lubricate threads and bearing face of the fastener to
obtain the proper fastener loading from these torque
Table 8. Ball Bearing Cooling Flow Rates values. Fasteners should be tightened evenly and in
(100 PSIG MAX.) stages. Refer to your torque wrench manual for the
proper use of your wrench.
Temperature Range Flow Rate
-20° to 300° F Table 9. Recommended Torque Values (ft-lbs)
Oil Lube - Air
(-4° to 149° C)
Temperatures above 300°F (149°C) not Bolt Size Material
recommended for OH1 configuration.
Steel 316
UNC Composite (or otherwise Stainless
*Constant Level Oiler. If equipped with a constant
level oiler, fill reservoir with oil, place thumb over spout, noted) Steel
invert and screw reservoir into upper casting. Allow 1/4”-20 5 5 7
reservoir to empty, filling the bearing frame (Figure 7). 5/16”-18 11 11 12
Several fillings of the reservoir may be required before 3/8”-16 18 18 21
the actual oil level is reached. To avoid adding too much
1/2”-13 33 39 45
oil, never finish filling oil in bearing frame (19) through
the vent breather (45) at top of the bearing frame. Never 5/8”-11 54 83 97
use lower casting only as a fill spout, always fill thru 3/4”-10 80 105 132
reservoir. When oil level is reached, no more oil will run 7/8”-9 109 160 203
out of the reservoir bottle. Use constant level oiler's 1”-8 144 236 300
glass sight to check oil level in bearing frame. When oil
Impeller Nut - 30 ft-lbs while holding the coupling end
level is reached tighten the three setscrews on the side
of the upper oiler. The constant level oiler (143) should of the shaft.
be topped up as required during operation.
Table 10. Recommended Equipment
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Maxum OH1 – I-402
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XI. SERVICE AND REPAIR. Prepare the pumping unit for disassembly using the
following list:
Refer to Figures 9 and 10 to locate the pump parts by
item number and parts list. 1. Read this entire section and study the
applicable sectional view drawing and parts list
A. PREPARATIONS FOR DISASSEMBLY OF PUMP. before disassembling the pump.
During disassembly, match mark parts so they can be
replaced in their original position. All parts should be DANGER
thoroughly cleaned or replaced with new, if necessary.
Sealing faces should be perfectly clean. Carver Pump Before attempting to disassemble the pump,
Company recommends that all O-rings and shims are the electrical power supply to the driver must
only used once. be locked and tagged in the “OFF” position to
prevent injury or death to personnel servicing
The back pull-out design of the pump enables the pump the pumping unit.
to be disassembled without disconnecting the piping or
removing the pump volute from the base. When the 2. Stop the pumping unit; refer to Section VIII,
pump is fitted with optional spacer coupling, the driver Paragraph G.
can also remain bolted on the base.
CAUTION
CAUTION
When pump is handling hazardous fluid,
extreme care must be taken to ensure safety of
Factory authorized parts must be used to
personnel when attempting to drain pump and
safely maintain your Carver Pump.
piping before disconnecting the pumping unit.
Suitable protection devices should be used
NOTE
and/or protective clothing should be worn.
To avoid damage to O-rings, check to make
sure all parts are free of sharp edges or burrs. 3. Remove capscrews (606), flatwasher (623) and
lockwasher (658) and remove seal guard (132).
Close suction and/or discharge valves. The pump volute 4. Disconnect piping, gauge lines, and auxiliary
should be cooled down to ambient temperature. The connections, as necessary.
volute must be empty and not under pressure. 5. Drain volute (1) by opening volute drain blind
flange (*422) or removing pipe plug (422). If
After prolonged operation, components may not be necessary, flush pump to remove corrosive or
easily removed from shaft. In such instances, rust toxic pumpage. Close volute drain blind flange
solvent may be used and suitable extracting tools when fluid is completely drained. Collect and
applied wherever possible. DO NOT use force under dispose of corrosive or toxic material
any circumstances. Refer to Table 10, Recommended appropriately.
Equipment, for proper tooling during disassembly and 6. Remove bearing frame pipe plug (420) in
assembly. Refer to appropriate sectional drawing for bearing frame (19) and drain oil. If a constant
location of parts followed by an item number. Assemble level oiler (143*) provides lubrication for ball
the pump in accordance with accepted rules of bearings, drain oil from the bearing frame by
engineering practice. Coat individual components with a removing bearing frame pipe plug at bottom of
suitable lubricant before assembling. Assembly of unit bearing frame. If bearings are mist lubricated,
should be performed on a clean, flat surface. drainage of bearing frame is continuous.
While assembling the pumping unit, Carver Pump 7. Remove hex nuts (619) from bolts (604 and
Company recommends that the following parts be 605). Remove lockwashers (659), flat washers
replaced with new: (621) and bolts (604 and 605) from coupling
guard (131). Remove bolts (603), flat washers
(621), and lockwashers (658) from fan
O-rings / Gaskets
shroud/coupling guard. Remove coupling guard
Shims
and disconnect coupling (42) halves. Remove
Ball Bearings coupling spacer between coupling halves.
Bearing Isolators 8. Remove hex nuts (614) from studs (634)
Mechanical seals holding volute (1) to base (23) if unit is being
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5. Inspect mechanical seal. Repair or replace Table 11. Factory Wear Ring Clearance (Inches)
mechanical seal that is extremely worn or
damaged. Factory Standard Diametric
Pump Size
6. Inspect impeller, fan, and coupling keys for Clearance (inch)
distortion and push fit into keyways. The keys Minimum Maximum
should be square on all four edges. They should
fit without having to be forced. The keys should AA- 1½ x 1 x 6 0.012 0.017
not rock in keyway. Replace keys or shaft if AB - 2 x 1½ x 6 0.015 0.020
necessary. AC- 3 x 1½ x 6 0.014 0.019
7. Inspect tubing for kinking. Replace kinked AD - 3 x 2 x 6 0.016 0.021
tubing. AE - 4 x 3 x 6 0.016 0.021
8. If the impeller shows excessive wear due to BA - 1½ x 1 x 8 0.012 0.017
erosion or pitting, so that performance cannot BB - 2 x 1½ x 8 0.012 0.017
be restored, it must be replaced. If a new
impeller is installed, check to make sure that it is BC - 3 x 1½ x 8 0.014 0.019
balanced and of the correct trim. BD - 3 x 2 x 8 0.016 0.021
9. Check the wear ring clearance as follows: BE – 4 x 3 x 8 0.017 0.022
a. Measure outside diameter of front impeller BF - 6 x 4 x 8 0.017 0.022
hub (2) in three places. CA – 2 x 1½ x 10 0.012 0.017
b. Measure inside diameter of volute wear ring CB - 3 x 1½ x 10 0.015 0.020
(7*) in three places. CC - 3 x 2 x 10 0.016 0.021
c. If difference between the high reading of the CD - 4 x 3 x 10 0.017 0.022
inside diameter of the volute wear ring (7*) CE - 6 x 4 x 10 0.018 0.023
and the low reading of the outside diameter CF - 6 x 6 x 10 0.018 0.023
of the impeller (2) hub exceeds double the
CG - 8 x 6 x 10 0.019 0.024
maximum clearances given in Table 11,
replace the volute wear ring according to DA - 2 x 1½ x 13 0.016 0.021
Section XI, Paragraph E. DB - 3 x 2 x 13 0.016 0.021
d. Measure outside diameter of back impeller DC - 4 x 3 x 13 0.017 0.022
hub (2) in three places. DD - 6 x 4 x 13 0.018 0.023
e. Measure inside diameter of the backhead DE - 6 x 6 x 13 0.018 0.023
wear ring (7X) in three places. DF - 8 x 6 x 13 0.020 0.025
f. If difference between the high reading of the DG - 10 x 8 x 13 0.021 0.026
inside diameter of the backhead wear ring DH – 12 x 10 x 13 0.023 0.028
(7X) and the low reading of the outside ED- 6 x 4 x 16 0.018 0.023
diameter of the back impeller (2) hub
exceeds double the maximum clearances EA- 8 x 6 x 16 0.020 0.025
given in Table 11, replace the backhead EB - 10 x 8 x 16 0.021 0.026
wear ring according to Section XI, ED - 12 x 10 x 16 0.023 0.028
Paragraph E. EC - 14 x 12 x 16 0.024 0.029
10. Check diameter of the discharge nozzle (224*) FA - 8 x 6 x 20 0.020 0.025
against the diameter listed on the nameplate FB - 10 x 8 x 20 0.021 0.026
and confirm they match. If they do not, replace
FC - 12 x 10 x 20 0.023 0.028
the discharge nozzle to the correct diameter that
matches the nameplate. FD – 14 x 12 x 20 0.025 0.030
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End Suction Process Pump 402 – 17.02.EN
values. Read this entire section before reassembling the 3. If removed, press radial ball bearing (16) on
pump. During reassembly, install parts as applicable. shaft (6). A bearing heater is recommended for
installation.
4. Install shaft (6) (with radial and thrust bearing
CAUTION
assemblies) from outboard end of bearing frame
(19) in bearing frame. Seating the thrust ball
During reassembly, install new locknuts, as
bearings (18) in the bearing frame.
they have a self-locking feature. Locknuts with
a self-locking feature may not provide adequate 5. Install new O-ring (89C) in groove provided
security once disturbed from position. around outboard end of bearing frame (19).
1. If removed, press thrust ball bearings (18) on Handle inboard bearing isolator (47) with care.
shaft (6). A bearing heater is recommended for Mishandling could damage faces of inboard
installation. Secure thrust ball bearings (18) with bearing isolator.
bearing lockwasher (69) and bearing locknut
(22). Crimp tang of lockwasher (69) in grooves 10. If removed, press inboard magnetic bearing
provided in bearing locknut (22). isolator (311*) into inboard bearing cap (35).
Install inboard bearing isolator (47) in inboard
2. If removed, install oil flinger (60*) on shaft (6) bearing cap.
and tighten flinger setscrew (864*).
11. Install gasket (73) on inboard bearing cap (35).
Install inboard bearing cap on shaft (6). Secure
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Maxum OH1 – I-402
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inboard bearing cap to bearing frame (19) with 24. Install coupling (42) spacer. Reconnect coupling
capscrews (601). halves. Align coupling according to Section VII,
12. Confirm backhead wear ring (7X) is in backhead Paragraph F.
(11). Install throttle bushing (63*) in backhead. 25. Reinstall coupling guard. Secure coupling guard
Install O-ring (89A*) on backhead. (131) with flatwashers (621), lockwashers (659),
and hex nuts (619), on bolts (604 and 605).
NOTE Secure coupling guard to fan shroud with bolts
(603), flatwashers (621), and lockwashers
Refer to mechanical seal vendor instructions for (658).
complete seal installation procedure. 26. Reconnect piping, gauge lines, and auxiliary
connections, as necessary. Confirm volute is
13. Install mechanical seal (90) on backhead (11) secure to base.
with hex nuts (615) on studs (630). Remove 27. Install seal guard (132) on bearing frame (11).
seal clip after mechanical seal installation is Secure seal guard with flatwashers (623),
complete. lockwashers (658), and capscrews (606).
14. Install backcover (11) to bearing frame (19) with
hex nut (617) and lockwasher (656) on stud
(632). WARNING
15. Install impeller key (32) in keyway on shaft (6).
16. Reinstall impeller (2) on shaft (6). Secure Pumps should be filled with oil before
impeller (2) with impeller washer (28) and starting the pumping unit. Operation of the unit
impeller nut (24) or inducer (24*). without proper lubrication can result in
17. Install pump coupling key (46) in shaft (6). overheating of the ball bearings, ball bearing
Install coupling (42) half on shaft. failures, pump seizures and actual breakup of
the equipment, exposing operating personnel to
injury.
CAUTION
28. Fill bearing frame with oil (refer to Section X,
Use a hoist with adequate lifting capacity; refer Paragraph A and Table 7). If ball bearings are
to Section VII, Paragraph B. oil mist lubricated, turn on system, wait for
proper oil quantity and check monitoring
18. Return assembly to installation site. system.
19. Confirm that forcing bolts (610) are below the 29. Remove all tags from valves and switches.
sealing surface of the backhead (11). Confirm 30. Start pumping unit in accordance with Section
volute wear ring (7*) is in volute (1). VIII, Paragraph C.
20. Install rotating element in volute (1). Secure
backhead (11) to volute with hex nuts (616) and
lockwashers (655) on studs (631 & 631X).
21. Install hex nuts (614) on studs (634) holding
volute (1) to base (23). Install capscrews (624)
and lockwashers (625) on bearing frame foot
holding bearing frame to base (23).
22. Rotate shaft (6) by hand to insure shaft (6)
rotates freely and no rubbing noises are
present.
23. If discharge nozzle (224*) was removed from
volute (1), make sure that locknut (673*) is still
attached to discharge nozzle. Install O-ring
(89D*) on discharge nozzle and install in volute.
Tighten locknut to secure discharge nozzle to
volute.
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E. REPLACEMENT OF WEAR RING. The pump has maximum to be sure the arbor and impeller are
a replaceable wear rings (7* and 7X) inserted into the running square.
volute (1) and backhead (11). The clearance between 8. Turn the front outside wear ring surface of the
the wear ring and impeller hub will increase with wear. impeller (2) until a 63 RMS or better finish is
Internal leakage will result and pump performance will obtained.
decrease. The allowable clearance and method of
9. Measure the outside diameter of the front
measurement is described in Section XI, Paragraph C.
impeller wearing surface and record this value.
See measurement instructions in Section XI,
NOTE
Paragraph C.
Parts marked with * are options that vary by 10. Mount the volute (1) with new volute wear ring
pumping unit and bearing frame size. (7*) installed in a lathe. Indicate female rabbet
to within 0.002 TIR maximum.
Refer to Section II for Safety precautions before NOTE
disassembling pump.
When replacing volute wear ring with the
Volute Wear Ring (7*).
standard volute wear ring, (part number
The volute (1) must be removed from the base to beginning with "00") machining in step 11 is not
replace the volute wear ring (7*). To replace the volute required. When replacing volute wear ring with
wear ring (7*) follow these steps: the undersize volute wear ring (part number
beginning with "US") machining in step 11 is
required.
CAUTION
11. If replacing with an undersized volute wear ring,
bore volute wear ring (7*) to within the specified
When pump is handling hazardous fluid, tolerance listed in Table 11 over the recorded
extreme care must be taken to ensure safety of size of the outside diameter of the front impeller
personnel when attempting to drain pump and wearing surface.
piping before disconnecting the pumping unit. 12. Reinstall volute (1) on base and secure with hex
Suitable protection devices should be used nuts (614) on studs (634).
and/or protective clothing should be worn.
13. Reassemble pump. Refer to Section XI,
1. Complete Section XI, Paragraph A before Paragraph D, steps 15 through 29.
continuing with disassembly.
Backhead Wear Ring (7X).
2. Remove impeller nut (24) and impeller washer
(28). Pull impeller (2) from shaft (6). Impeller
key (32) may come off with impeller. CAUTION
3. Disconnect suction and discharge piping.
Remove hex nuts (614) from studs (634) to
remove volute (1) from base and take volute When pump is handling hazardous fluid,
and impeller (2) to a work area with access to extreme care must be taken to ensure safety of
machine shop equipment. personnel when attempting to drain pump and
4. Remove the volute wear ring (7*) from the piping before disconnecting the pumping unit.
volute (1). This can best be accomplished on a Suitable protection devices should be used
lathe. and/or protective clothing should be worn.
5. Press the new volute wear ring (7*) into the
1. Complete Section XI, Paragraph B, steps 1
volute (1). The beveled edge of the volute wear
through 6 before continuing. Remove backhead
ring is installed away from the impeller (2).
(11) with backhead wear ring (7X) still installed
6. Secure the new volute wear ring (7*) to the and the impeller (2) to a work area with access
volute (1) by tack welding in two places 180 to machine shop equipment.
degrees apart along edge of volute wear ring.
2. Remove the backhead wear ring (7X) from the
7. Place impeller (2) on an arbor and mount backhead (11). This can best be accomplished
between centers in a lathe or a grinder. Indicate on a lathe.
front outside impeller hub to within 0.002 TIR
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Maxum OH1 – I-402
End Suction Process Pump 402 – 17.02.EN
3. Press the new backhead wear ring (7X) into the NOTE
backhead (11). The beveled edge of the
backhead wear ring is installed away from the When replacing backhead wear ring with the
impeller (2). standard backhead wear ring, (part number
4. Secure the new backhead wear ring (7X) to the beginning with "00") machining in step 9 is not
volute (1) by tack welding in two places 180 required. When replacing backhead wear ring
degrees apart along edge of backhead wear with the undersize backhead wear ring (part
ring. number beginning with "US") machining in step
9 is required.
5. Place impeller (2) on an arbor and mount
between centers in a lathe or a grinder. Indicate
back outside impeller hub to within 0.002 TIR 9. If replacing with an undersized backhead wear
ring, bore backhead wear ring (7X) to within the
maximum to be sure the arbor and impeller are
specified tolerance listed in Table 11 over the
running square.
recorded size of the outside diameter of the
6. Turn the back outside wear ring surface of the back impeller wearing surface.
impeller (2) until a 63 RMS or better finish is
obtained. 10. Reassemble pump. Refer to Section XI,
Paragraph D, steps 12 through 30.
7. Measure the outside diameter of the back
impeller wearing surface and record this value. F. MOTOR. The motor should be maintained in
See measurement instructions in Section XI, accordance with the manufacturer’s instructions.
Paragraph C.
8. Mount the backhead (11) with new backhead G. CHECK VALVE. If applicable, the check valve
wear ring (7X) installed in a lathe. Indicate should be maintained in accordance with the
female rabbet to within 0.002 TIR maximum. manufacturer’s instructions.
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End Suction Process Pump 402 – 17.02.EN
XII. PARTS LISTS AND DRAWINGS. for this pumping unit. Refer to Figure 9, the Sectional
Assembly and Figure 10, Pump with Base, drawings for
This section contains listings of parts and corresponding the location of parts identified by item numbers.
drawings. Table 12 notes the recommended spare parts
Table 12. Recommended Spare Parts List
Item
Description
Number
1 Volute
2 Impeller
6 Shaft
*24 Inducer
*Option
Figure 8. Inducer
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Item Item
Description Description
Number Number
1 Volute 421 Pipe Plug – Oil Mist Port
2 Impeller *422 Blind Flange - Volute Drain
6 Shaft *532 Male Connecter - BT
7 Wear Ring – Volute *564 Male Connecter - 90 degrees
7X Wear Ring - Backhead 590 Hose Clamp – Frame Cooling Fan
11 Backhead 601 Capscrew – I.B Cap / Frame
15X Shim – Motor / Base 602 Capscrew – Oil Pan
16 Ball Bearing, Radial 603 Capscrew – Fan Shroud / Guard
18 Ball Bearing, Thrust 604 Bolt – Coupling Guard
19 Bearing Frame 605 Bolt – Coupling Guard
22 Bearing Locknut 606 Capscrew – Seal Guard
23 Base 607 Bolt - Drain Flange
24 Impeller Nut 608 Bolt – Motor / Base
*24 Inducer 609 Bolt – Coupling Guard / Fan Shroud
28 Impeller Washer 610 Forcing Bolt
32 Key, Impeller *611** Foot Leveling Bolt
32F Key, Fan *612** Adjusting Bolt - Motor
35 Bearing Cap, Inboard *613** Bolt – Adjusting Block/Base
37 Bearing Cap, Outboard 614 Hex Nut – Volute/Base
40 Fan, Frame Cooling 615 Hex Nut – Seal
42 Coupling 616 Hex Nut – Volute
45 Vent Breather 617 Hex Nut - Backhead
46 Coupling Key - Pump 618 Hex Nut – Fan Shroud
46X Coupling Key - Motor 619 Hex Nut – Coupling Guard
47 Bearing Isolator – IB 620 Flatwasher – Drain
49 Bearing Isolator – OB 621 Flatwasher – Fan Shroud
*60 Oil Flinger 622 Flatwasher – Coupling Guard
*63 Throttle Bushing 623 Flatwasher – Seal Guard
69 Bearing Lockwasher 624 Capscrew – Frame Foot/Base
73 Gasket, Frame - Cap 625 Lockwasher – Foot/Base
*73A** Gasket, Auxiliary Piping 630 Stud – Seal
*73B Gasket, Drain 631 Stud – Volute / Adaptor
*73C Gasket, Volute 631X Stud – Volute / Adaptor (Guide)
*81** Motor Adjusting Block 632 Stud – Backhead
*89A O-Ring, Backhead-Volute 633 Stud – Bearing Cap
89B O-Ring, Oil Pan 634 Stud – Volute/Base
89C O-Ring, Bearing Cap 654 Lockwasher – Volute / Base
90 Mechanical Seal 655 Lockwasher – Volute / Backhead
131 Guard, Coupling 656 Lockwasher – Adaptor / Frame
131A Fan shroud 657 Lockwasher – Cap / Frame
132 Guard, Seal 658 Lockwasher – Seal Guard / Guard
*143 Oiler 659 Lockwasher – Coupling Guard
190 Electric Motor 660 Lockwasher – Motor / Base
200 Motor 668 Setscrew – Fan
215 Oil Pan 670 Locknut – Fan Shroud
*310** Bearing Isolator – IB, Magnetic 671 Stud – Fan Shroud
*311** Bearing Isolator – OB, Magnetic 672 Flatwasher – Fan Shroud
*410 Tubing - Cooler *864 Setscrew – Flinger
420 Pipe Plug – Bearing Frame *890** Vibration Transmitter, RTD, ETC
* Option ** Not Shown
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End Suction Process Pump 402 – 17.02.EN