Service instructions

CRK 2 model A, B and C

CRK 4 model A and B

50Hz 3~
60 Hz 1/3~

Table of contents
1. Type identification ........................................................................................................................... 2
1.1 Nameplate ........................................................................................................................................ 2
1.2 Type key ............................................................................................................................................ 3
2. Torques and lubricants ................................................................................................................... 4
3. Shaft seals........................................................................................................................................ 4
4. Service tools .................................................................................................................................... 5
4.1 Special tools ...................................................................................................................................... 5
4.2 Standard tools.................................................................................................................................... 5
4.3 Torque tools....................................................................................................................................... 6
5. Dismantling and assembly ............................................................................................................. 7
5.1 Dismantling ........................................................................................................................................ 7
5.2 Assembly ........................................................................................................................................... 8
6. Order of assembly for chambers and impellers ......................................................................... 10
6.1 Symbol survey ................................................................................................................................. 10
6.2 Stage survey.................................................................................................................................... 11

02.09.2002 GB 1 / 14
1. Type identification
This section shows the nameplate, the type key and the codes that can appear in the variant code.

1.1 Nameplate

1 2 3 4 5

Type
CRK 2-70/7 A-W-A- AUUV
Model C 40900007 P1 0204
Q 2,5 m3/h Q 1,4 m3/h
H 45,5 m H 17 m 9
6 -2
n 2900 min n 3420 min-1 10

TM02 5528 3502

7
t 90 °CMAX
8 11
Made in Denmark
12
13

Pos. Description Pos. Description

1 Type designation, see section 1.2 Type 8
Speed, 50 Hz
key
2 Model 9 Rated flow rate, 60 Hz
3 Product number 10 Head at rated flow rate, 60 Hz
4 Place of production 11 Speed, 60 Hz
5 Production year and week 12 Max. temperature
6 Rated flow rate, 50 Hz 13 Country of production
7 Head at rated flow rate, 50 Hz

02.09.2002 GB 2 / 14
1.2 Type key
Example CR K 2- 70 /7 X- X- X- XXXX

Type range
Cooling lubricant / condensate
Rated flow rate m³/h, 50 Hz
Number of stages x 10
Number of impellers
Code for pump version:
A = Basic version
U = NEMA version
Code for pipework connection
Code for materials:
A = Basic version:
Pump head: cast iron
Other wetted parts: stainless steel DIN W.-Nr. 1.4301, AISI 304

I= All wetted parts: stainless steel DIN W.-Nr. 1.4401,

1.4408, AISI 316 or 316LN
Code for shaft seal:
BUBV = Rubber bellows seal; rotating face: tungsten carbide;
stationary seat: synthetic resin-impregnated carbon; O-rings: V=FKM

AUUV = O-ring seal; rotating face: tungsten carbide;

stationary seat: tungsten carbide; O-rings: V=FKM

02.09.2002 GB 3 / 14
2. Torques and lubricants
This section shows the screws and nuts that must be tightened to a certain torque and the lubricants to be
used.

Pos. Description Dim. Torque [Nm] Lubricant

M6 x 20 13
9 Screw
M8 x 25 31
M6 x 20 5 Thread-eze
28 Screw
M8 x 20 12
36 Nut M10 20
67 Lock nut M8 12
Gardolube
84b Screw M4 2

Thread-eze, part no. SV9997 (0.5 l).

Gardolube L 6034, part no. SV9995 (1 l).

3. Shaft seals

Type
CRK 2-50/3 AWA BUBV
Model C
Q m3/h Q m3/h
(1) (2) (3) (4)
H m H m A- W- A- BUBV
n min-1 n min-1
t °CMAX

988349

A
1
BUBV
CRK A/B/C
AUUV 2

1 2

105

105
TM01 9197 1400

02.09.2002 GB 4 / 14
4. Service tools
The following drawings and tables show special, standard and torque tools for pump service.
A B C D

E F G H

I J K L

4.1 Special tools

Pos. Description For pos. Suppl. information Part no.
A Shaft holder for dismantling SV0237
B Punch for removing the shaft SV0238
C Puller for neck ring SV0239
D Shaft holder for assembly SV0040
E Mounting ring SV0872
F Mounting band SV0871

4.2 Standard tools

Pos. Description For pos. Suppl. information Part no.
28 M6 - 10 mm SV0083
G Ring/open-end spanner 28 - 67 M8 - 13 mm SV0055
36 M10 - 17 mm SV0056
M6 - 5 mm SV0124
H Tee key 9
M8 - 6 mm SV0050

02.09.2002 GB 5 / 14
4.3 Torque tools
Pos. Description For pos. Suppl. information Part no.
4 - 20 Nm 9 x 12 SV0292
I Torque wrench
20 - 100 Nm 9 x 12 SV0269
28 M6 - 10 mm 9 x 12 SV0310
J Ring insert tool 28 - 67 M8 - 13 mm 9 x 12 SV0294
36 M10 - 17 mm 9 x 12 SV0270
K Open-end insert tool 36 M10 - 17 mm 9 x 12 SV0617
M6 - 5 mm ½" x ½" SV0296
L Hexagon socket driver M-9 M8 - 6 mm ½" x ½" SV0297
M10 - 8 mm ½" x ½" SV0298
M Rachet insert tool I-L 9 x 12 x ½" x ½" SV0295

02.09.2002 GB 6 / 14
5. Dismantling and assembly
If it is necessary to dismantle the pump, either because it is choked or damaged, please follow the instruc-
tions below.
Before dismantling, switch off the power supply to the motor. Remove the discharge pipe and the supply
cable.
The cable should be removed in accordance with local regulations.
Remove the bolts (screws) holding the pump to a possible condensate tank.
The pump is now free and can be lifted out of the tank.
Position numbers, see “Parts list” and section 4. Service tools.

5.1 Dismantling
Slacken the screws, pos. 7a, and remove them together with the coupling guards, pos. 7, or remove the
coupling guards from the pump head, pos. 2, using a screwdriver.
Remove the screws, pos. 9, the coupling, pos. 8, and the shaft pin, pos. 10.
Slacken and remove the screws, pos. 28, holding the motor to the pump. The motor is now free and can be
removed.
Slacken and remove the nuts, pos. 36, together with the washers, pos. 66a. Then remove the straps,
pos. 26.
The following parts can now be removed:
• from the bottom of the pump:
pull ring/retainer for strainer, pos. 121, strainer, pos. 84, screws, pos. 84b and retainer for strainer, pos.
84a.
• from the top of the pump:
pump head, pos. 2, gasket, pos. 37, adapter flange, pos. 2k, and gasket, pos. 37a.
Pull the rotating shaft seal part free of the shaft.
The seal ring should not be exposed to blows or knocks.
Hold the shaft by means of a screwdriver inserted in the shaft pin hole while the nut, pos. 67, is slackened.
Remove the nut, the washer, pos. 66, and the priming screw, pos. 122.
Place the shaft holder, pos. A, in a vice and tighten it. Place the pump body in the shaft holder with the
threaded shaft end pointing upwards.
Screw the punch for dismantling, pos. B, on the threaded shaft end.
The first chamber to be removed is always a chamber with bearing ring, pos. 4a. See also section 6. Order
of assembly for chambers and impellers.
Make sure that the chamber is positioned in the recess of the shaft holder and that the shaft can pass freely
through and underneath the shaft holder.
Drive the punch down through the impeller hub by means of a hammer. Remove the free parts from the
shaft.
Repeat the procedure until the shaft passes through the shaft holder, pos. A.
Take care not to damage the shaft when it is driven free of the last impeller and the spacer, pos. 61.
Remove the punch, pos. B, from the threaded shaft end.
If the stop ring, pos. 62, is damaged, push it out of the recess and pull it free of the spline (towards the
threaded end of the shaft).
• Pump head
Prise the stationary shaft seal part out of the pump head by means of a nylon punch or a similar tool.
The stationary shaft seal part must not be exposed to blows or knocks.
• Neck ring
Free the neck ring, pos. 45, by pushing up the neck ring retainer, pos. 65, by means of the puller,
pos. C.

02.09.2002 GB 7 / 14
5.2 Assembly
Before assembly, clean and check all parts.
Parts which are defective or do not comply with the measurements mentioned below due to wear should be
replaced by new parts.
Nut for shaft, gaskets and O-rings should always be replaced when the pump is overhauled.
• Bearing
The maximum permissible difference between the diameters of the bearing ring, pos. 47a, and the bear-
ing in the chamber, pos. 4a, is 0.4 mm.
• Pump head
Moisten the stationary seal ring with O-ring and the recess of the pump head with water. Press the seal
ring home in the pump head with the O-ring against the pump head.
The seal ring must not be exposed to blows or knocks.
• Impeller
The impeller must fit into the neck ring. If the tolerance (clearance) between neck ring and impeller is too
big, replace the worn part.
• Neck ring
Place the neck ring, pos. 45, on the chamber. Then place the retainer, pos. 65, on the neck ring and
press it until it engages with the chamber.
It must be possible to move the neck ring freely (sideways) between the retainer and the chamber.
Note: No neck ring is fitted in the chambers, pos. 3, 3a and 5a.
Place the shaft holder, pos. D, in the vice. Place the shaft, pos. 51, in the shaft holder and tighten the vice.
The threaded end of the shaft must be uppermost, and the opposite end must be flush with the lower edge
of the shaft holder.
Press the stop ring, pos. 62, down over the spline and home in the recess of the shaft.
Continue the assembly, see section 6. Order of assembly for chambers and impellers.
Fit the nut, pos. 67, and tighten it to the torque stated, see section 2. Torques and lubricants.
Fit the straps into the slits of the retainer for strainer.
Fit the mounting band, pos. F, in the middle of the pump and tighten it.
Slacken the vice and lift the pump body off the shaft holder.
Place the pump body in the mounting ring, pos. E, with the smooth shaft end pointing upwards.
Fit the adapter flange, pos. 2k, with gasket, pos. 37a, on top of the pump body.
Fit the rotating shaft seal part, see section 3. Shaft seals. Moisten the rubber part with water.
Make sure that the O-ring is not damaged on the shaft pin hole and that the seal rings are not exposed to
blows or knocks.
Fit the rotating seal ring so that the mark in the driving dog and the smooth (lapped) face point upwards.
Before fitting the pump head, pos. 2, check that the stationary shaft seal part and the gasket, pos. 37, are
positioned correctly.
Lubricate the seal faces of the seal rings with silicone oil, type VO170038.
Lubricate the seal faces only.
Fit the pump head to the pump body so that the threaded ends of the straps engage with the holes of the
pump head.
Lubricate the nuts, pos. 36. Fit the nuts and tighten diagonally to the torque stated, see section 2. Torques
and lubricants.
Fit the motor and turn it to the required terminal box position. Lubricate the screws, pos. 28. Fit the screws
and tighten diagonally to the torque stated, see section 2. Torques and lubricants.
Fit the shaft pin, pos. 10, in the shaft. Fit the coupling, pos. 8. Lubricate the screws, pos. 9. Fit the screws,
tighten and leave loose.
Check that the gaps either side of the coupling halves are equal.
Raise the pump body as far as possible by means of a large screwdriver or a similar tool inserted under-
neath the coupling. Take care not to raise the motor shaft.
Lower the pump body 1-1.5 mm from its top position and tighten the screws two and two (same side), see
section 2. Torques and lubricants.

02.09.2002 GB 8 / 14
Check that the gaps either side of the coupling halves are equal and check the pump by turning the coupling.
If the pump is tight or it cannot be rotated, a further adjustment should be carried out.
Spring the two coupling guards, pos. 7, into place or secure them by means of the screws, pos. 7a.
Remove the mounting band, pos. F.
The pump is now assembled. Check the head and flow according to test specification, see below.

CRK 2 96436595
CRK 4 96436597

02.09.2002 GB 9 / 14
6. Order of assembly for chambers and impellers
1. Determine the pump type (CRK 2 or CRK 4) and the stage variant. Find the pump in the relevant stage
survey table.
2. Find the components of each stage in the symbol survey.
This survey also contains pumps with fewer chambers than impellers. These pumps are not part of the
standard range and therefore not shown in the WinCAPS product range.

6.1 Symbol survey

84b
84
3a 3a 4 4 4 4a 4a
121

47a 47a
67
69 69 66b
69a 69a 64
122
64a 64a 64c

TM01 9199 1400

5a

61 61 49 49
49d

02.09.2002 GB 10 / 14
6.2 Stage survey
6.2.1 CRK 2

160 178 196 214 232 250

CRK 2-
20/ 30/ 40/ 50/ 60/ 70/
2 1 3 2 1 4 3 2 1 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1
1
2
3
4

L
5
6
7
8

286 322 358

CRK 2-
90/ 110/ 130/
9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6
7

L
8
9
10
11
12
13
14

394 448

CRK 2-
150/ 180/
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6
7
8
9

L
10
11
12
13
14
10
11
12
13
14

520

CRK 2-220/

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6
7
8
9
10
11
L

12
13
14
15
16
17
18
TM01 9200 1400

19
20
21
22
23

02.09.2002 GB 11 / 14
 592

CRK 2-260/

26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6
7
8
9
10
11
12
13

L
14
15
16
17
18
19
20
21
22
23
24
25
26
27

1005

CRK 2-500/

26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
L

26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
TM01 9201 1400

48
49
50

02.09.2002 GB 12 / 14
6.2.2 CRK 4

169 196 223 250 277 304

CRK 4-
20/ 30/ 40/ 50/ 60/ 70/
2 1 3 2 1 4 3 2 1 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1
1
2
3
4

L
5
6
7
8

331 385 439

CRK 4-
80/ 100/ 120/
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6

L
7
8
9
10
11
12
13

493 547

CRK 4-
140/ 160/
14 13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6
7
8

L
9
10
11
12
13
14
15
16
17

628

CRK 4-190/

19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6
7
8
9
10
L

11
12
13
14
15
16
TM01 9376 1400

17
18
19
20

02.09.2002 GB 13 / 14
 709

CRK 4-220/

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6
7
8
9
10
11

L
12
13
14
15
16
17
18
19
20
21
22
23

1005

CRK 4-330/

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
L

18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
TM01 9377 1800

33
34

02.09.2002 GB 14
14 / 14