Operating and Maintenance Instructions VM No.: 460.

0008 GB
Edition: 07.01
Ident No.: 550 102

Volute–Casing Centrifugal Pumps Retain

for future
Series NTT and CTT use!

Order No.: Pump Ident. No.:

Machine No.: Pump Type:

Operating data, dimensions and other additional information can be found in the order–specific part of the
documentation.

Contents
These Operating and Maintenance 1. General
Instructions contain information from
the pump manufacturer. They may need 2. Safety
to be supplemented by instructions of
the operator company for its personnel. 3. Transportation and Intermediate
These instructions do not take account Storage
of specific information relating to opera-
tion and maintenance of the process 4. Description
plant into which the pump is integrated.
Such information can only be given by 5. Installation/Mounting
the persons responsible for construc-
tion and planning of the plant (plant 6. Start–up/Shutdown
manufacturer).
Such specific instructions relating to 7. Maintenance/Repair
operation and maintenance of the
process plant into which the pump is
8. Operating Faults, Causes and
integrated have priority over the
Remedial Action
instructions of the pump manufac-
turer. The plant manufacturer must
on principle observe the limits of 9. Associated Documentation
use!

Refer to the operating instructions of

the plant manufacturer! Important note:
This operating manual is to be supplemented
by the order–related informations.

1
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1 General
1.1 Pump designation
The exact designation can be found in the order–spe-
cific documents (see data sheet).

1.2 Proper use

Information on proper use of the pumps is provided in
the technical data sheet.
The pumped liquid must not contain any abrasive con-
stituents nor corrode the pump materials.

1.3 Performance data

The exact performance data can be taken from the or-
der data sheet and/or acceptance test report.

1.4 Warranty
Our warranty for shortcomings in the supply is laid
down in our delivery conditions. No liability will be un-
dertaken for damages caused by non–compliance with
the operating instructions and service conditions.
If at any later date the operating conditions change (e.g.
different fluid conveyed, speed, viscosity, temperature
or supply conditions), it must be checked by us from
case to case and confirmed, if necessary, that the pump
is suited for those purposes. Where no special agree-
ments were made, pumps supplied by us may, during
the warranty period, only be opened or varied by us or
our authorized contract service workshops; otherwise
our liability for any defects will cease.

1.5 Testing
Prior to leaving our factory, all pumps are subjected to
a leak test. Additional tests will only be performed on re-
quest.

1.6 Availability
As a matter of principle, we recommend stocking
replacement pumps and withdrawable units (hydraulic
action system) where the supplied pumps are a
decisive factor in maintaining a production or delivery
process. In this way downtimes can be avoided, or
reduced to a minimum.

1.7 Pressure limit

The sum of inlet pressure and maximum delivery pres-
sure must not be greater than the permissible internal
pump pressure (see data sheet).

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2 Safety
These operating instructions contain basic safety 2.3 Dangers in the event of non–compliance with
instructions for installation, operation and safety instructions
maintenance. It is therefore essential that they are read Failure to comply with the safety instructions may result
by fitters and all specialist staff and customer personnel in danger to persons, and place the environment and
prior to installation and start–up. They must always be the machine at risk. Non–compliance with the safety
kept at hand at the place of installation. instructions will lead to the loss of any claims for
damages.
The special safety instructions contained in the other Non–compliance may result in the following dangers:
chapters must be observed in addition to the general
safety instructions in this chapter. S Failure of important functions of the plant

2.1 Identification of safety instructions in the S Failure of specified methods for maintenance and
operating manual servicing
The safety instructions contained in these operating
instructions which represent a danger to personnel if S Danger to persons resulting from electrical,
not complied with are specially marked by the general mechanical and chemical effects
danger symbol:
S Danger to the environment resulting from leakage of
hazardous substances

2.4 Responsible working practices

The safety instructions contained in these operating
Warning symbol instructions, current national accident prevention
as per DIN 4844–W9 regulations, as well as internal working, operating and
safety rules of the customer, must be observed.
Warning of danger from electric voltage is indicated as
2.5 Safety instructions for the user/operator
follows:
S Hot or cold machine parts representing a danger
must be protected against accidental contact on
site.

S Protection against accidental contact for moving

Warning symbol parts (such as the coupling) must not be removed
as per DIN 4844–W8. while the machine is in operation.

S When operating pump aggregates in a dust–laden

Instructions which are essential to avoid endangering environment (e.g. milling, chipboard manufacture,
the machine and its operation are marked by the word bakeries), the surfaces of the pumps and motors
must be cleaned at regular intervals, depending on
ATTENTION local conditions, in order to maintain the cooling
effect and eliminate the possibility of spontaneous
combustion. Please also see explosion protection
Instructions affixed directly to the machine such as regulations (ZH 1/10).

S Directional markers S Leakage (e.g. from the shaft seal) of hazardous

substances being handled, such as explosive, toxic
S Signs for fluid connections or hot materials, must be discharged in such a way
that no danger to persons or the environment is
must always be observed and maintained in fully created. Legal regulations must be observed.
legible condition at all times.
S Dangers from electrical energy must be eliminated.
2.2 Personnel qualification and training For details in this regard, please refer to VDE and
The operating, maintenance, inspection and mounting local power company regulations.
personnel must be appropriately qualified for the duties
assigned to them. The scope of their responsibilities,
competency and supervisory duties must be closely
controlled by the customer. If the personnel do not have
the required knowledge, they must be trained and
instructed. If required, this may be provided by the
manufacturer/supplier on behalf of the customer. The
customer must additionally ensure that personnel fully
understand the content of the operating instructions.

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2.6 Safety instructions for maintenance, inspection 3 Transportation and Intermediate Stor-
and installation
The operating company must ensure that all
age
maintenance, inspection and installation tasks are 3.1 Packaging
performed by authorized and qualified specialist Attention must be paid to the figurative markings on the
personnel who have thoroughly studied the operating packaging.
instructions. The suction and pressure side and all auxiliary connec-
Work on the machine is only to be carried out when the tions must always be closed during transportation and
machine is at a standstill. The procedure for shutting storage.
down the machine described in the operating The coverings must only be removed im-
instructions must always be followed. mediately before connecting the pipeline.
Pumps or aggregates handling fluids which are
detrimental to health must be decontaminated. All 3.2 Transportation
safety and protective devices must immediately be The pump or pump aggregate is to be safely trans-
refitted and made operational on completion of the ported to the place of installation, if required by means
work. of lifting gear.
The instructions under Section 6.1, ”Preparation for
start–up”, must be observed before restarting. The regulations for lifting loads in accordance with
VBG 9a must be observed. Crane and sling equip-
2.7 Unauthorized conversion and production of ment must be adequately dimensioned. Sling
replacement parts equipment must not be secured to the lifting eyes
Conversion or modification of the machines is only of the motor, except as additional protection
permissible after consultation with the manufacturer. against overturning in the event of nose–heavi-
Original replacement parts and accessories approved ness.
by the manufacturer are intrinsic to safe operation. If
other parts are used the manufacturer cannot be held Transportation to and at the installation site
liable for the consequences. Make sure that the unit is transported safely and in a
stable position. Overturning due to nose–heaviness
2.8 Unacceptable modes of operation must be prevented.
The operational safety of the machine supplied is only
ensured when it is used in accordance with Section 1 of
the operating instructions. The limit values given on the
data sheet must not be exceeded under any
circumstances.

Transport damage
Check the pump for damage on receipt.
Any damage detected must be notified im-
mediately.

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3.3 Preservation / Storage of centrifugal pumps Note: The preservatives listed are to be regarded as a
recommendation. Alternatively, technically equivalent
3.3.1 Preservation products from other manufacturers can be used.
In the case of storage or prolonged standstill, the When handling preservatives, the safety hints con-
pumps must be protected against corrosion. In those tained in the relevant DIN safety data sheets and those
cases, an outside and inside preservation is to be pro- of the manufacturer must be complied with.
vided. The durability of the protection against corro-
sion, which is limited in time, depends on the composi- 3.3.1.4 Depreservation
tion of the preservative to be applied and the storage Prior to setting the pump in motion, the inside preserva-
conditions. tion must be removed.
Under normal circumstances the pumps Environmentally compatible disposal must be en-
have no special preservative. sured.
At an additional charge we can, however, supply
pumps and replacement parts ex factory with a preser- Preservatives can be removed with wax solvents, pe-
vative adequate to the planned storage period. troleum ether, diesel, petroleum or alkaline cleaners.
However, the simplest method is to use a steam clean-
3.3.1.1 Outside preservation er.
The outside preservative should be applied by painting Recommendation for Tectyl 506 EH: Allow petro-
or spraying with a spray gun. leum ether to act for 10 minutes before any further ac-
tion.
Points of preservation:
All bright and unvarnished parts (e.g. shaft ends, cou- Pumps that are used in the food or drinking water sector
plings, flange facings, valve and manometer connec- must be dismantled and thoroughly cleaned prior to de-
tions). preservation.
A suitable solvent that is compatible with the liquid to be
3.3.1.2 Inside preservation
pumped (drinking water/food) can be used as the
(Not required for pumps made of stainless materials.)
cleaning agent, e.g. Spiritus, Ritzol 155 or suds with a
high alkaline content. Steam cleaning is ideal.
Internal preservation is applied by painting, spraying
using spray guns, filling/dipping and subsequent drain-
After a prolonged storage period (more
ing. Finally, the suction and outlet branches as well as
than 6 months), all elastomers (O–rings,
all other supply and discharge branches must be shaft seals) must be checked for elasticity of shape.
sealed with dummy flanges or dummy plugs (plastic Embrittled elastomers must be replaced. EP rubber
caps). elastomers (EPDM) must be replaced on principle.
Points of preservation: 3.3.2 Storage
All bright parts inside the pump (e.g. pump casing in- During storage of the pump, the suction and outlet
side, bearing bracket, shafts, impellers and diffusers). branches and all other supply and discharge branches
must always be closed with dummy flanges or dummy
3.3.1.3 Storage times
plugs.
Depending on the required storage period and the sur-
Storage should be in a dry, dust–free room. During stor-
roundings, we recommend the use of preservatives
age, the pump should be cranked at least once a
from Valvoline GmbH, Hamburg.
month. During this process, parts such as the shaft and
bearings should change their position.
Storage in a closed, dry and dust–free room
3.3.3 Monitoring of preservation
Storage time up to 6 months up to 12 months over 12 months À The preservation must be checked at regular intervals.
Internal preserrvation Tectyl 511 M Tectyl 511 M Tectyl 506 EH The preserved areas must be inspected every 6
External preservation Tectyl 511 M Tectyl 511 M Tectyl 506 EH months and re–treated, if necessary.
We cannot accept any liability for defects
Storage in the open–air, central European climate that arise due to incorrect preservation
treatment.
Storage time up to 6 months up to 12 months over 12 months
Internal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH
External preservation Tectyl 542 Tectyl 506 EH Tectyl 506 EH

Storage in the open–air, tropical climate, aggressive industrial air or

proximity to the sea

Storage time up to 6 months up to 12 months over 12 months Â

Intermal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH
External preservation Tectyl 506 EH Tectyl 506 EH Tectyl 506 EH

À Internal and external preservation must be renewed after 48 months at the latest.
Á External preservation must be renewed after 18 months at the latest.
Internal preservation must be renewed after 48 months at the latest.
 External preservation must be renewed after 12 months at the latest.
Internal preservation must be renewed after 48 months at the latest.

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4 Description / Principle design of the pump
The pictorial presentation may not correspond with the pump supplied.
The actual design will be stated in the specific order documents.

Volute casing

Bearing bracket

Impeller

Safety stuffing box Shaft Shaft seal

Contact protection to EN 809

by coupling guard

Earthing connection to EN 809

at the base plate

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5 Installation/Mounting

5.1 Installation 5.2.3 Characteristics of a floor/concrete foundation

For installation methods and locations, please see in- The foundation must be horizontal, flat and clean, and
stallation drawing. be capable of bearing the full load upon it.
Note: Concrete foundations must be executed with
Other methods of installation are not permissible standard concrete of strength class B 25 as a minimum.
without prior consultation with the manufacturer.
5.3 Alignment of the pump aggregate
The safety regulations and tests in accordance The pump aggregate must be aligned to its pre–set
with DIN 4754 and VDI 3033 must be observed height and system dimensions. This is done using sui–
where pumps are installed in heat–transfer plants. table steel shims, arranged directly adjacent to each fi–
xing bolt.
When installing the pump, please ensure The overall height of the steel shims is determined by
that the cooling air from the motor fan can the established system dimensions of the plant. The
flow unimpeded over the bearing bracket to the casing steel shims and the base plate must be positioned
cover. evenly and securely.
If the fixing holes are more than 750 mm apart, we re–
5.1.1 Place of installation commend fitting additional steel shims in the middle of
Temperature: min. –20
C the base plate.
max. +40
C

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Base plate

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
relative air humidity:
permanent max. 85 %
temporary

Installation height:
max. 100 %

max. 1000 m above NN

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Steel shims
= =
Foundation
> 750

For data differing from this, please consult the manu- Fig. 1: Alignment with steel shims
facturer.
Intensive vibrations in the vicinity of the
pump unit can lead to bearing damage and Horizontal alignment of the aggregate is produced by
must therefore be avoided. way of flat–machined surfaces on the pump using a
machine spirit level. Measurements are taken in longi–
5.1.2 Protective devices tudinal and transverse directions of the pump aggre–
In order to prevent injuries due to burns, at pumping gate.
liquid temperatures higher than 60
C protective de- Permissible deviation: max. 1 mm per 1 m length.
vices in accordance with EN 809 must be provided on
site. 5.3.1 Fixing the pump aggregate
In order to prevent deformation of the base plate/pump,
Heat insulation this must first of all be screwed tightly at three points.
Only the volute housing may be insulated Before tightening the rest of the screws, spacers
with heat insulating material. In order to should again be positioned around the screw, in order
enable optimum heat dissipation no other pump com- to balance out the unevenness of the seating.
ponents may be insulated. The prescribed tightening torque (Section
7.2.3) must be observed.
5.2 Foundation
Precise details on the shape and dimension of the fixing
5.2.1 General
are provided in the installation drawing.
The foundation may be a floor/concrete base or a load–
bearing steel foundation frame. 5.3.2 Checking the alignment
The foundations must be constructed in After aligning and tightening the screws, it must be
such a way that they can take the weight of possible to turn the pump and drive by hand, without
the pump unit and all operating forces that occur. any strain.
Note: The pump unit should not be welded to the base
5.2.2 Characteristics of a steel foundation frame
for technical installation reasons.
A steel foundation frame must be constructed in such a
way that pump feet or base plate are supported evenly
and can be secured with screw fixings.
If the base plate is only supported at four
points the pump aggregate will hang down
in the middle. This will affect the alignment of the cou-
pling and may also lead to severe noise being gener-
ated.

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5.4 Checking the coupling alignment

5.4.1 Adjusting the support foot

Before aligning the coupling, all screws on the support
foot (183...) must be loosened, so that the insert unit is
stress–free. After aligning the coupling, screw the sup-
port foot (183...) down to the base plate. The fixing
screw (901...) on the bearing bracket should still be
loose. Check that the bearing bracket is not twisted dur-
ing tightening. For this purpose, the fixing screw (901...)
must screw freely into the bearing bracket. If this is not
possible, the seat of the support foot on the base plate Figure 5.3: Alignment of the coupling with dial gauges
must be corrected (e.g. by placing spacer plates under-
neath). Then tighten the fixing screw (901...). Note: The permissible axial and radial deviation,
measured on the front face of the coupling and the
5.4.2 Checking the coupling alignment in case of hori-
coupling circumference respectively, may be max.
zontal setup on base plate
0.1 mm, but as far as possible should be kept below
A complete delivered pump aggregate has been care–
0.05 mm.
fully assembled at the factory. After proper installation,
and prior to start–up of the pump aggregate, the align–
If a height, lateral or angle offset is detected between
ment of the coupling must be checked.
the two coupling halves, the drive motor should be re–
The check can be made with a straight–edge and a
aligned such that the coupling halves are flush with
feeler gauge, or with other suitable equipment (such as
each other (level out with flat packing shims as neces–
a laser alignment device).
sary).
The measurements are taken in two planes, each offset
Whe the fixing bolts have been aligned and tightened
by 90_, on the circumference of the coupling.
the pump/drive motor unit must be able to be spun by
hand without pressure points.
The gap between the two coupling halves must be the
Out–of–flush errors on the coupling may
same all round the circumference of the coupling. The
lead to heavier wear of the coupling, the
specified gap is shown in the installation diagram.
anti–friction bearing and the shaft seal, and even cause
the shaft end to be torn off.
The spacing between the straight–edge laid over both
coupling halves and the respective shaft must be the 5.4.3 Coupling alignment of special designed couplings
same all round the circumference. (if present)
Refer to the operating instructions of the coupling
manufacturer.

5.5 Assembly of pump and drive motor

If the aggregate is only assembled at the place of use,
Straight–edge the following work is to be performed:

1. Coat the pump and motor shaft ends with a fine film
of molybdenum disulfide (e.g. Molykote) and insert
keys.

2. Push on the coupling halves on the pump and motor

Feeler gauge side with the aid of a pusher device until the shaft
end is flush to the coupling hub.
If no puller is available, heating the coupling halves
Figure 5.2: Alignment of the coupling with to approx. 100
C (without rubber buffer) facilitates
straight–edge and fee–ler gauge pushing.
The possibility of shock and stress on
For couplings with a distance piece (removable coup- the pump and drive motor components
lings) the alignment of the coupling can be checked must be eliminated.
with dial gauges.
3. Tighten the grub screw on both coupling hubs.

4. When assembling the pump and motor, make sure

the specified gap between the coupling halves is
maintained (see our installation drawings).

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5. In the case of horizontally mounted pump Shorter pipelines on the suction side are
aggregates fixed on a base plate or directly on the possible, but may lead to a deterioration of
foundation, the coupling must be aligned as the hydraulic performance data. Shorter pipelines on
described in Section 5.4. the discharge side are possible, but may lead to in-
creased noise development.
6. Mount the contact protection.
According to accident prevention regulations, the Compensators must not generate any un-
pump must only be operated with a protection acceptable additional forces on the pump
against accidental contact. connection branches. Special care is needed in cases
where compensators are used, whose pressurised di-
Note: When installing pumps with symmetrical feet ameter is greater than the nominal width of the pump
which are supplied without base plate, make sure that connection branches.
the guide bolt at the volute casing is seated in a guide
hole. The hole diameter must be provided according to 5.7.2 Changes in cross–section and direction
the representation below. The 5 mm distance must be Sudden changes in cross–section and direction, as
observed. well as bends with a bend radius less than 1.5 times the
interior pipe width, must be avoided.

5.7.3 Supports and flange connections

All pipelines must be connected to the
pump stress–free in accordance with
VDMA standard sheet 24277.
The permissible pipeline forces must not
be exceeded in any operating status.
We therefore recommend on principle that a calculation
of the pipeline forces is performed, which takes into
consideration all operating status (e.g. cold/warm,
Fig. 5.4: Volute casing with guide bolt in the base plate empty/full, depressurised/pressurised, etc.).
Pipeline supports must always be free sliding and must
5.6 Space required for maintenance and repair not rust in (check regularly).
The pump must be accessible from all
sides in order to be able to carry out How to assess a pipeline connection
necessary visual inspections. To conduct an assessment, the pipeline must be de-
Adequate space must be provided for maintenance pressurised, completely drained and cooled. The
and repair work. It must also be ensured that all pumping liquid must be disposed of with respect for the
pipelines can be attached and removed without environment.
hindrance.
S Disconnect the pipeline from the pump at the con-
5.7 Laying the pipelines necting flanges.
S After disconnecting the connecting flanges, the
5.7.1 Nominal widths pipeline must be freely movable in all directions in
The nominal diameters of the pipelines need not the area of expected expansion.
necessarily correspond to those of the inlet and outlet Note: up to Ø 150 mm by hand
branch, however, they must not be smaller. Different from Ø 150 mm with small lever
nominal diameters of suction branches and suction
pipelines are to be compensated by centric transition S The flanges must lie plane–parallel.
pieces. Formation of air bags is to be avoided.
5.7.4 Cleaning pipelines prior to attachment
Prior to assembly, all pipeline parts and valves must be
Figure DN 1 thoroughly cleaned.
Recommendation for straight pipeline No impurities must reach the pump from
length before and after the pump
the pipeline system (e.g. welding beads,
residues from preservatives, etc.).
In these areas, pipe fittings such as gate
min. 5xDNd

Flange gaskets must not protrude inwards. Blanking

valves, bends, compensators etc. should
flanges, plugs, protective film and/or protective paint on
be avoided wherever possible.
flanges and seals must be removed completely.
Filters on suction side must be cleaned
regularly. We recommend monitoring with
differential manometer and/or contact manometer.

5.7.5 NPSH observation

The NPSH conditions of the system must be adapted to
the respective pump requirement (NPSHreq.).
An essential condition is fulfilled if the system NPSH va-
lue (NPSHavail.) is at least 0,5 m above the pump
min. 5xDNs
NPSH value (NPSHreq.). The NPSHreq. can be taken
from the characteristic curves of the relevant pumps.

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The applicable NPSH values in the char- 5.9 Electrical connections
acteristic curves are for water with 20
C. The power supply cables of the drive motor must be
For other media and/or temperatures, the NPSH value connected by a trained electrician, according to the
may deviate from the characteristic curves. motor manufacturer’s circuit diagram. The valid VDE
regulations, the regulations of the local electricity board
Uncertainties in the determination of and the operating manual for the motor must be
NPSH conditions, particularly for media complied with.
other than water and/or other temperatures, must be Danger due to electrical power must be excluded and
compensated for by increased safety factors (please an EMERGENCY STOP switch in accordance with EN
consult the manufacturer). 809 must be provided.
5.7.6 Inlet pipeline The pump must not run dry, not even for
In order to avoid the formation of air bags, the inlet checking the sense of rotation.
pipeline must be laid rising to the pump.
Refer 6.1... Control of drive motor sense of rotation
5.7.6.1 Stop valve (inlet mode)
A stop valve is to be installed in the inlet pipeline. It must
be fully open during operation (see figure DN 1). 5.10 Checking the pressure of the system with built–in
pump
5.7.7 Pressure pipeline If the whole system with built–in pump is to be sub-
jected to a final pressure test, the test pressure must
5.7.7.1 Stop valve in the pressure pipeline not be more than the maximum permissible internal
A stop valve should be installed in the pressure pipe- pressure of the pump (see data sheet).
line.

5.7.7.2 Non–return valve in the pressure pipeline

The pump must not run backwards. It is recommended
that a non–return valve is fitted between the pressure
branch and the stop valve.

5.7.7.3 Bleeding
In the pressure pipeline, bleeding facilities should be
provided at the highest point and in front of the non–re-
turn valve.

5.7.8 Auxiliary connections

The positions of the auxiliary connections on the pump
are shown in the installation drawing. All auxiliary
pipelines must be connected in accordance with the
installation drawing, stress–free and sealed.

5.8 Safety and control devices

5.8.1 Manometers
We recommend to provide suitable pressure gauges in
the inlet and pressure pipelines, and in the pressurized
auxiliary pipelines.

5.8.2 Thermometers
Thermometers must be provided to monitor the tem-
perature of the delivery fluid.

5.8.3 Safety devices in the inlet, delivery and auxiliary

pipelines
Safety devices in the form of stop valves must be
installed in the pipelines, if not already provided, to
allow the pipelines to be shut off and disconnected
during maintenance and repair work.

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6 Start–up/Shutdown

When starting up and shutting down the pump(s), 6.1.3 Control of drive motor sense of rotation
general and special safety requirements for heat The sense of rotation of the motor must match the
conducting equipment (e.g. from DIN 4754, VDI sense of rotation arrow on the pump. To check the
3033, etc.) must be observed as well as the appli- sense of rotation, the motor can be switched on briefly
cable accident prevention regulations (e.g. UVV/ when the pump is full.
VBG 64). The pump must not run dry, not even for
Plant manufacturers and operators are respon- checking the sense of rotation.
sible for informing personnel of safety require- In the case of pumps with a mechanical seal that is de-
ments, as well as for the implementation and con- pendent on the sense of rotation, the motor must al-
tinued observation of the same. ways be disconnected in order to check the sense of
rotation.
If the sense of rotation is incorrect, the sense of rotation
6.1 Preparations for (initial) start–up of the three phase motor can be reversed by switching
any two phases.
6.1.1 Filling and bleeding the pump in the plant
Prior to starting up, the pump must be bled in the plant. 6.2 Start–up
For this, the plant and the pump must be filled with de-
livery fluid (see plant manufacturer’s operating instruc- 6.2.1 General
tions). Before starting, all filling and venting openings must be
During filling with delivery fluid, we recommend slowly completely closed.
rotating the pump shaft by hand to allow air pockets to
escape into the piping system. 6.2.2 Checking the coupling alignment
If the pump fails to build up pressure when started up Prior to starting and after the first run–up of the pump to
(see manometer), bleeding must be repeated. operating temperature, the coupling alignment and the
fixing of the supporting foot is to be checked. Readjust,
6.1.2 Filling and bleeding the bearing bracket if necessary (please refer to Section 5.4 above). The
Due to the sealing effect of the safety stuffing box, the pump shaft must be capable of being cranked by hand
bearing bracket must be separately filled with heat and without any pressure points.
transfer oil.
6.2.3 Starting
To avoid overloading the drive motor, the pump should
be run up only against a closed pressure stop valve dur-
ing starting.
The stop valve in the inlet pipeline must be fully open.

6.2.4 Drive
Switch on the motor.
Refer to the operating instructions of the drive motor
manufacturer.

6.2.5 Minimum rate of flow

Immediately after reaching the operating speed, the
For bleeding and filling, the screw plugs of connections pressure–side stop valve must be opened and the
V and FF are removed and at connection FF, clean heat pump operated up to at least the minimum rate of flow
transfer oil of the same quality as the liquid pumped is (see data sheet).
filled in until same emerges at connection V. In order to
achieve a good flow it may be required to heat up the Note for pumps in high temperature plant:
heat transfer oil prior to filling. First, heat the plant to 100 – 130
C with the pump run-
ning. For these purposes, the stop valve on the supply
The connections must be resealed imperviously after side must be completely opened. Run the pump and
filling and bleeding. plant at this temperature until uniformly warmed
through and fully de–aerated. Then heat up to operat-
During bleeding of the pump and the plant, hazardous
ing temperature slowly.
or environmentally harmful fluid and gas emerging
must be safely collected and discharged. The plant manufacturers’ instructions con-
cerning heating–up of the plant have prior-
ity over the above general recommendations.

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6.2.6 Setting the pump power output values 6.4 Measures in the event of standstills
The pressure–side stop valve must be opened until the
required pump power output values are obtained (see Pumped liquid Measures in the event of Measures in the event of
brief standstill prolonged standstill
data sheet). ...

Until the operating temperature has been May solidify

reached, it may be necessary to run the + Hear or drain pump Drain pump
has a preservative effect À
pump at a reduced capacity. This will compensate for
May solidify
the increased power consumption due to high viscosity. + Drain and preserve pump
Hear or drain pump
does not have a preserva- À
tive effect
6.2.7 Temperature
In order to prevent injuries due to burns, at pumping Does not solidify
+
liquid temperatures higher than 60
 protective de- has a preservative effect
– –

vices in accordance with EN 809 must be provided on À

site. Does not solidify

+ Drain and preserve pump
–
does not have a preserva- À
It must be ensured that the pump housing tive effect

is evenly heated. Differences in tempera-

ture between the top and bottom of the pump, as well as À See section 3.3
sudden temperature changes, should be avoided.
Temperature changes in the material of more than
50°C per minute are not permissible.

6.2.8 Spare pump

A spare pump belonging to the plant must always be
kept ready for operation. For these purposes, the stop
valve on the supply side must be completely open. The
stop valve on the outlet side must be opened to such a
degree that the pump, filled and bleeded, has operating
temperature.

In plants in which impermissible tempera-

ture may arise due to failure of the operat-
ing pump, a standby pump of sufficient output must be
provided.
Two independent energy sources must be provided for
the operating and standby pumps.

6.3 Shutdown

S Pressure pipeline
If a non–return valve is installed in the pressure pipe-
line, the stop valve can remain open. Without non–
return valve, the stop valve must be closed.

S Drive
Switch off the motor. Make sure the pump runs down
smoothly and evenly.

S Inlet line
Close stop valve in inlet line.

It must be ensured that the pump does not run back-

wards after switching off. Otherwise, the pump may
reach unacceptably high speeds, and shaft seals de-
pendent on the direction of rotation will be severely da-
maged.

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7 Maintenance/Repair

7.1 Maintenance The pump side medium–lubricated rolling bearing is

maintenance–free.
S The instructions in Section 2, Safety, must be
observed in maintenance and repair work. The drive–side rolling bearing is lubricated with special
grease and is filled with grease at the factory.
S Regular monitoring and maintenance of the pump
and the drive motor are essential for optimum ser- S Bearing bracket size 360 and 470:
vice life and safety. Sealed rolling bearing with guard discs, provided
with a lifetime grease filling at the factory.
7.1.1 General monitoring
S Bearing bracket size 530 and 650:
Open rolling bearing with Nilos rings and grease
1. The pump must not run dry.
filled at the factory. These bearings must be regu-
larly relubricated.
2. The pump must not run in cavitation.
For the relubrication periods, please refer to the fol-
3. The minimum delivery rate must always be main- lowing listing.
tained (see Section 6.2..).
Speed Bearing bracket size
4. The drive motor must not be overloaded. 530 650

5. The bearing temperature of rolling bearings must min–1 Lubrication period in operating hours
not exceed 
 1450 11.400 10.500

6. The shaft seal must have no inadmissible leakage. 1750 10.100 9.300

7. The pump unit must not experience or generate any Notes:

undue vibrations (e.g. as a result of incorrect align-
1. At a maximum ambient temperature of 35
C and
ment). International standard ISO 10816 must be re-
maximum admissible operating temperature, the
ferred to for assessment.
temperature at the drive–side rolling bearing is ap-
prox. 70
C. Higher ambient temperatures or bad
8. Changes to the normal operating data may indicate
ventilation may cause higher temperatures.
faults. The causes must be established.
2. In case of temperatures over 70
C, the lubrication
9. Installed standby pumps must be started up once a
week. period for 15
C each temperature rise must be re-
duced to one half!
Note: In addition, the instructions for erection, oper-
ation and servicing of heat transfer plants according to 3. Unfavourable operating and ambient conditions
DIN 4754 and VDI 3033 are to be observed. such as dust, high air humidity, aggressive atmos-
phere etc. may require even shorter lubrication
periods.
7.1.2 Maintenance of components
Fill with grease
7.1.2.1 Bearing
S Fill hollow spaces between the rolling bodies up to
The nominal service life of the bearing is designed for a
approx. 40% with grease.
minimum of 2 years continuous operation, in accord-
ance with DIN ISO 281. The actual usable life may be Bearing Rolling bearing Grease quantity
lower, due to intermittent operation, high temperature, bracket size Abbreviation in grams
low viscosity, vibrations or the like. 530 6410 J C4 ca. 35
The running noises and the temperature in the bearing 650 6413 J C4 ca. 65
area must be checked at regular intervals. We recom-
mend monitoring bearings by means of shock pulse S Scrape off excess grease (most suitably with your
measurements. If damage to a bearing is detected, the fingers; do not use metal objects).
bearing must be replaced.
The bearing area can become very hot.
Risk of burning if touched!

As a precautionary measure, we recommend that

the ball bearings are replaced every 2 years.

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Rolling bearing greases: 7.2 Repair
For the lubrication of the drive–side bearing, the below–
listed rolling bearing grease or an equivalent special General
grease with the following characteristics must be used. The system operator is responsible for ensuring that in-
struction in safety is provided. The personnel must be
Quality: made aware of all hazards that can arise in connection
The rolling bearing grease must be free from resin and with the pumped liquid or the plant.
acid and anti–corrosive.
Mounting and repair work
Characteristics: Trained Service fitters are available on request to carry
Worked penetration 250–280 mm/10 out mounting and repair work.
Dropping point > 250
C For all repairs, it must be ensured that the pump is de-
Range of temperature pressurised, completely drained and cool. The motor
application: -40 bis 180
C must be protected against unintended switching on.
We must refuse acceptance of repair work on pumps
Manufacturer Brand filled with fluid, for the protection of our staff and for
environmental reasons. The expenditures for disposal
Klüber À ASONIC GHY 72 with respect to the environment are to be carry by the
À Manufacturer: KLÜBER LUBRICATION MÜNCHEN KG customer/operating company.
Geisenhausenerstr. 7
81379 München Hazardous substances
Germany Where repairs are to be carried out on pumps which
have been operated with hazardous substances À
and/or environmentally harmful media, the
7.1.2.2 Shaft seal customer/operator must inform its own personnel on
The built–in mechanical seal is maintenance–free. site, or our personnel where repairs are returned to our
A maximum dripping rate of 10 g/h may occur during factory or a service workshop, without being
operation and is normal. If the dripping is heavier, the specifically requested to do so.
shaft seal must be replaced. Together with the request for a Service fitter a
verification of delivery material, for example in the form
A defective shaft seal can cause uncontrolled dis- of a DIN safety data sheet, must be submitted to us.
charge of pumping liquid. Alternatively, you can request a certificate of safety
This constitutes a hazard to people (possibility of (form no. 448/191) from our Service department, filling
spraying liquid) and to the environment! it out truthfully, correctly and in full. Send the completed
form to the center commissioned with carrying out the
At the site, it must be assured by the operator that the repair, or hand it to our Service fitter.
seepages drained through seepage drain LO are safely
and completely collected in a closed tank. À Hazardous substances are:

7.1.2.3 Coupling S Toxic substances

Following initial start–up, after first heating of the pump S Health–endangering substances
to operating temperature and at regular intervals, the S Corrosive substances
alignment of the coupling and the condition of the flex- S Irritants
ible elements in the coupling is to be checked (please S Explosive substances
refer to Section 5.4 above). S Fire–inducing substances
Note: Worn flexible elements are to be replaced. S Highly flammable, easily flammable and normally
flammable substances
7.1.2.4 Drive S Carcinogenic substances
Refer to the operating instructions of the motor S Substances impairing fertility
manufacturer. S Genetically distorting substances
S Substances in other ways hazardous to humans

Pumps or units which pump hazardous substances or

substances that are dangerous to the environment
must be completely decontaminated.

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7.2.1 Dismounting the centrifugal pump 7.2.2 Mounting the centrifugal pump
Before dismounting, the following work must be carried Before remounting check all parts for wear
out: and aging and, as necessary, replace with
original replacement parts.
S Electrical danger must be eliminated! The motor Clean all parts before mounting. Always fit new
must be secured against being switched on. If gaskets.
necessary, the power supply cable must be
disconnected from the motor by an authorized
electrician. The pump must be mounted by a qualified techni-
cian using the pertaining drawings. The prescribed
S Close all stop devices in the inlet and delivery pipe- tightening torque must be observed.
line, and in the auxiliary pipelines. To prevent damage, it is especially important to ensure
that the components are mounted concentrically and
S Allow the pump housing to cool to ambient that they are not tilted.
temperature.
Mounting instructions:
S Drain the fluid in flowable condition from the pump.
Note: Use a collecting tank. S The markings applied when dismounting must be
observed. The components must be put back in their
S The pump must be depressurized and drained. original fitting position.

S Hazardous substances and/or environmentally S When assembling, screws and nuts must be painted
harmful media must be drained off and collected with a suitable high–temperature screw paste (e.g.
such that no danger to life and limb is created. Molykote P37).
Environmentally compatible disposal must be
ensured. S After fitting the insert unit, the pump shaft must lie
exactly flush with the motor shaft.
S Remove auxiliary pipelines, if fitted.
S After tightening the screws, it must be possible to
S Dismount manometer lines, manometers and hold- turn the pump and drive manually without straining
ing devices. points.
S Dismount protection against accidental contact.
7.2.3 Tightening torque
The pump must be dismounted by a qualified Note: With poor and lightly greased surfaces, the va-
technician using the pertaining drawings. lues must be increased by 10–15%, in order to reach
To prevent damage, it is especially important to ensure the required performance.
that the components are dismounted concentrically
and that they are not tilted. Tightening
Part no. Thread Quality torque
Dismounting instructions: [Nm]

S The pumps are produced as standard in process de- 902.1

920.1 M 10 35
sign. This means that the insert unit can be dis- 8.8
901.01 M 12 60
mounted without the need to remove the volute GA–T2
902.01 M 16 146
housing and the pipes. 920.01
901.02 M 12 8.8 60
S If a coupling with a distance piece is used, the motor 902.02 M 16 GA–T2 146
can remain on the base plate during this process.
901.03
M 10 8.8 35
901.14
S The fitting position of all components must be accu-
rately marked before dismounting. 901.13
M 12
8.8
31
M 16 146
903.1
903.2
903.02 G 1/4 10
903.06 G 3/8 St 15
903.07 G 1/2 30
903.18
903.19
M6 9
914.4
M8 8.8 22
914.08
M 10 35
M 20 x 1,5 112
922.2 M 24 x 1,5 188
1.7139
922.01 M 30 x 1,5 340
M 36 x 1,5 700

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Following the mounting the centrifugal pump, the 7.3 Replacement parts
following operations are to be performed. The application guidelines in accordance with DIN 24
296 can be taken as a basis for spare parts stock hold-
S Align coupling (please refer to Section 5.4 above). ing (see Section 7.3.2).

S Attach protection against accidental contact and However, for reasons of operational safety, we recom-
supporting foot, if any. mend the stocking of complete insert units or spare
pumps.
S Attach manometer pipelines, manometer and hold- Advantage: In the event of damage, a defective unit
ing devices to the pump. can be replaced by a spare unit without great expendi-
ture and in a very short space of time.
S Electrical danger must be eliminated! Power supply
cables must only be connected by qualified 7.3.1 Ordering spare/replacement parts
electricians. Pay attention to sense of rotation. The following details are required for handling orders
for replacement and spare parts:

Start up pump as per instructions in Section 6. S Pump abbreviation À

S Pump number À
S Year of construction À
S Part number
S Denomination
S Quantity

À refer to name plate

7.3.2 Replacement parts for two–year continuous operation as per DIN 24 296

Part No. Part denomination Number of identical pumps (including standby pumps)

2 3 4 5 6 und 7 8 und 9 10 und mehr

Set/Replacement parts quantity

171.1 / 01 Diffuser (all two–stage pump sizes) 1 1 1 2 2 3 30%

210... À Shaft with distance washer 551.1 / 551.04

distance washer 551.3 / 551.05
impeller nut 922.2 / 922.01
circlip 932.2 / 932.02
circlip 932.7 / 932.07 1 1 2 2 2 3 30%
spring ring 930.1 / 936.01
spring washer 930.2 / 934.01
key 940.1 / 940.01
key 940.2 / 940.02

230.1 / 01 Impeller (all single–stage pump sizes) 1 1 1 2 2 3 30%

230.2 / 02 Impeller first stage and

230.3 / 03 Impeller second stage with À
1 1 1 2 2 3 30%
514.1 / 01 Threaded ring and
904.5 / 05 Hexagon socket with cup point

321.1 / 01 Groove ball bearing 1 1 2 2 3 4 50%

321.2 / 02 Groove ball bearing 1 1 2 2 3 4 50%

– Cartridge–unit pump, consisting of:

Bearing bracket, casing cover, shaft, – – – – – 1 2
À
groove ball bearing etc.

433.1 / 01 Mechanical seal, complete 2 3 4 5 6 7 90%

461.1 / 01 Stuffing box packing (set) 2 2 3 3 3 4 40%

Gaskets for pump casing (set)

diverse À 4 6 8 8 9 12 150%
Other gaskets (set)

À Can be purchased as assembly group/sale group.

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8 Operating Faults, Causes and Remedial Action

8.1 Faults with reference number for cause and remedial action
The table below is intended as a guide to identifying faults and their possible causes.

If faults occur which are not listed here, or which cannot be traced back to the listed causes, we recommend consulting the
factory, or one of our branch offices or sales offices.

The pump must be depressurized and drained when faults are being rectified.

Centrifugal pump faults Reference numbers for cause and remedial action
Delivery rate too low 1, 2, 3, 4, 5, 6, 7, 8, 9, 21, 22
Delivery head too low 2, 3, 4, 5, 6, 7, 8, 9, 21, 22
Power consumption of pump too high 9, 11, 12, 16, 17, 21, 22, 25
Delivery pressure too high 9, 12
Bearing temperature increased 16, 17, 18, 20, 25
Pump housing leaky 23
Heavy leakage of shaft seal 10, 13, 16, 17, 27
Pump not operating smoothly 1, 2, 3, 4, 5, 6, 8, 11, 16, 17, 24, 25, 26
Pump gets hot 2, 5, 26

8.2 Causes and remedial action

Ref. no.: Cause Remedial action

1 Delivery head higher than nominal delivery head 1. Open stop valve in pressure pipeline until operating point is
of pump. reached.
2. Install impeller with larger diameter.
3. Increase rotation speed (turbine, frequenzy control, ...). À
2 Pump or pipelines not properly bled or filled. Bleed and top up pump or pipelines.
3 Inlet pipeline or impeller blocked. Clean pipelines and impeller.
4 Air pockets forming in pipeline. Perhaps install a vent valve, or lay pipeline differently.
5 NPSHplant (inlet) too low. 1. Check fluid level in inlet tank.
2. Open stop valve in inlet pipeline fully.
3. Lay inlet pipeline differently if friction losses are too high.
4. Check filter in inlet pipeline, if fitted.
5. Check inlet flow conditions of pump.
6 Wrong direction of rotation of pump. Reverse polarity of any two phases on motor.
7 Rotation speed too low. Increase rotation speed (turbine, frequenzy control, ...). À
8 Excessive wear on inner pump parts. Replace worn parts.
9 Density or viscosity of delivery medium does not Consult the factory in the event of faults due to non–compliance
comply with pump design data. with design data. À
10 Shaft sleeve damaged. Mount new shaft sleeve.
11 Delivery head lower than nominal delivery head 1. Regulate operating point with stop valve in pressure pipeline.
of pump. 2. Turn off impeller in event of continuous overload.
12 Rotation speed too high. Reduce rotation speed (turbine, frequenzy control, ...). À
13 Shaft seal damaged. Check shaft seal parts for wear and replace if necessary.
14 – –
15 – –
16 Pump aggregate wrongly aligned. Re–align pump as described.
17 Pump twisted. Check pipelines for twists in connections.

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18 Excessive axial thrust. Clean relief bore holes in impeller.

19 – –
20 Specified coupling half gap not complied with. Set coupling half gap as per installation diagram.
21 Motor voltage incorrect. Use motor with correct voltage.
22 Motor runs only to two phases. 1. Check cable connection.
2. Replace fuses.
23 Screws not tight. 1. Tighten screws.
2. Replace gaskets.
24 Impeller out–of–true. 1. Clean impeller.
2. Re–balance impeller.
25 Groove ball bearing defective. Replace groove ball bearing.
26 Delivery rate below minimum. Increase delivery rate to minimum.
27 Pumped liquid corroding mechanical seal mate- Check pumped liquid (e.g.: incorrect temperature, concentra-
rial. tion, dosing of additives, etc.)

À Consult factory

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9 Associated Documentation
Sectional drawing NTT
Sizes at bearing bracket size 360 und 470

Design with intermediate ring

View X

Sectional drawing NTT

Sizes at bearing bracket size 530 und 650

Shaft seal: Uncooled, unbalanced mechanical seal with safety stuffing box
Abbreviation: U5A

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Sectional drawing NTT
Two–stage sizes at bearing bracket size 360

Shaft seal: Uncooled, unbalanced mechanical seal with safety stuffing box
Abbreviation: U5A

Denomination Part No. Denomination Part No. Connections

–––––––––––––––––––––––––––––––––––––– –––––––––––––––––––––––––––––––––––––– –––––––––––––––––––––––
Volute casing 102.01 Distance washer 551.01 FD Draining
Stage casing 108.01 Distance washer 551.04 FF Filling
Casing cover 161.01 Distance washer 551.05 LO Leakage outlet
Casing cover 161.02 Rivet 565.01 V Bleeding
Diffuser 171.01 Rivet 565.02
Supporting foot 183.01 Pipe 710.01
Shaft 210.01 Hexagon screw 901.01
Shaft 210.02 Hexagon screw 901.02
Impeller 230.01 Hexagon screw 901.03
Impeller first stage 230.02 Hexagon screw 901.13
Impeller second stage 230.03 Stud bolt 902.01
Groove ball bearing 321.01 Screw plug 903.02
Groove ball bearing 321.02 Screw plug 903.06
Bearing bracket 330.01 Screw plug 903.07
Bearing cover 360.02 Screw plug 903.09
Gasket 400.01 Grub screw 904.05
Gasket 400.02 Socket–head cap screw 914.08
Gasket 400.03 Nut 920.01
Joint ring 411.02 Impeller nut 922.01
Joint ring 411.06 Circlip 932.01
Joint ring 411.07 Circlip 932.02
Joint ring 411.09 Circlip 932.04
Mechanical seal 433.01 Spring washer 934.01
Stuffing box packing 461.01 Spring ring 936.01
Intermediate ring 509.01 Key 940.01
Threaded ring 514.01 Key 940.02
Spacer sleeve 525.02 Key 940.03
Claming sleeve 531.01 Name plate 971.01
Washer 550.01 Information plate 972.01

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Sectional drawing CTT
Sizes at bearing bracket size 360 und 470

Shaft seal: Uncooled, balanced mechanical seal with safety stuffing box
Abbreviation: U5.1A
View X

Sectional drawing CTT

Sizes at bearing bracket size 530 und 650

View Y
symmetrical feet

Shaft seal: Uncooled, balanced mechanical seal

with safety stuffing box
Abbreviation: U5.1A
VM 460.0008 GB/07.01 – Ident–Nr. 550 102 21
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Sectional drawing CTT
Two–stage sizes at bearing bracket size 360

Shaft seal: Uncooled, balanced mechanical seal with safety stuffing box
Abbreviation: U5.1A

Denomination Part No. Denomination Part No. Connections

–––––––––––––––––––––––––––––––––––––– –––––––––––––––––––––––––––––––––––––– –––––––––––––––––––––––
Volute casing 102.1 Distance washer 551.4 FD Draining
Stage casing 108.1 Spring dowel 560.2 FF Filling
Casing cover 161.1 Rivet 565.1 LO Leakage outlet
Diffuser 171.1 Rivet 565.2 PM2 Pressure measurement
Supporting foot 183.1 Pipe union 730.4 V Bleeding
Shaft 210.1 Hexagon screw 901.13
Impeller 230.1 Hexagon screw 901.14
Impeller first stage 230.2 Stud bolt 902.1
Impeller second stage 230.3 Screw plug 903.1
Groove ball bearing 321.1 Screw plug 903.2
Groove ball bearing 321.2 Screw plug 903.18
Bearing bracket 330.1 Screw plug 903.19
Bearing cover 360.2 Grub screw 904.5
Gasket 400.1 Socket–head cap screw 914.4
Gasket 400.13 Hexagon nut 920.1
Joint ring 411.1 Impeller nut 922.2
Joint ring 411.2 Spring ring 930.1
Joint ring 411.18 Spring washer 930.2
Joint ring 411.19 Circlip 932.2
Mechanical seal 433.1 Circlip 932.6
Stuffing box packing 461.1 Circlip 932.7
Threaded ring 514.1 Key 940.1
Washer 550.6 Key 940.2
Distance washer 551.1 Name plate 970.1
Distance washer 551.3 Information plate 970.2

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Order–specific Documentation
These operating instructions are supplemented by the following documents:

Acceptance of order No.

Data sheet No.
Installation drawing No.
Sectional drawing No.
Part list No.

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Subject to technical alterations.

A Member of the
COLFAX PUMP GROUP
ALLWEILER AG S Werk Radolfzell
Postfach 1140 S 78301 Radolfzell
Allweilerstraße 1 S 78315 Radolfzell
Germany
Tel. +49 (0)7732 86-0
Fax +49 (0)7732 86-436
E-mail: [email protected]
Internet: http://www.allweiler.com

VM 460.0008 GB/07.01 – Ident–Nr. 550 102 24