Grundfos CR 95 Betriebsanleitung

CR, CRN 95 to 255

50/60 Hz

Service instructions

GRUNDFOS INSTRUCTIONS

CR, CRN 95 to 255

English (GB)

Service instructions ........................................................................4

Table of contents

English (GB) Service instructions

Original service instructions

Table of contents

1. General information ........................4

1.1 Hazard statements..........................4

1.2 Notes ..................................4

1.3 Safety .................................5

1.4 Contaminated products .......................5

1.5 Servicing the motor .........................5

2. Preparing the dismantling of the product ..........5

2.1 Lifting the product ..........................5

3. Dismantling and assembling the product ..........6

3.1 Motor and coupling .........................6

3.2 Shaft seal, motor stool, pump head cover, sleeve and

chamber stack ............................6

3.3 Thrust-handling device ......................10

4. Renewing thrust-handling-device wear parts .......12

4.1 Chamber stack ...........................12

5. Renewing chamber wear parts ................16

5.1 Neck ring (45)............................16

5.2 Bush (47c) and retaining ring (47d) ...............18

6. Renewing shaft seal wear parts ...............18

6.1 Dismantling .............................18

6.2 Assembly ..............................19

7. Additional information .....................20

7.1 Torques ...............................20

7.2 Lubricants ..............................20

7.3 Special service tools........................21

7.4 Order of assembly for chambers and impellers........23

7.5 Drawings...............................24

8. Document quality feedback ..................30

1. General information

Read this document before you install the product.

Installation and operation must comply with local

regulations and accepted codes of good practice.

1.1 Hazard statements

The symbols and hazard statements below may appear in Grundfos

installation and operating instructions, safety instructions and

service instructions.

DANGER

Indicates a hazardous situation which, if not avoided, will

result in death or serious personal injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious personal injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate personal injury.

The hazard statements are structured in the following way:

SIGNAL WORD

Description of the hazard

Consequence of ignoring the warning

• Action to avoid the hazard.

1.2 Notes

The symbols and notes below may appear in Grundfos installation

and operating instructions, safety instructions and service

instructions.

Observe these instructions for explosion-proof products.

A blue or grey circle with a white graphical symbol

indicates that an action must be taken.

A red or grey circle with a diagonal bar, possibly with a

black graphical symbol, indicates that an action must not

be taken or must be stopped.

If these instructions are not observed, it may result in

malfunction or damage to the equipment.

Tips and advice that make the work easier.

English (GB)

1.3 Safety

DANGER

Electric shock

Death or serious personal injury

‐Switch off the power supply before you start any work

on the product.

‐Make sure that the power supply cannot be switched

on accidentally.

WARNING

Falling objects

Death or serious personal injury

‐Follow the lifting instructions.

‐Use lifting equipment which is approved for the weight

of the product.

‐Keep the product in a stable and fixed position when

working on it.

‐Persons must keep a safe distance to the product

during lifting operations.

‐Wear personal protective equipment.

For lifting instructions, see the instructions provided with the

product.

WARNING

Corrosive liquids

Death or serious personal injury

‐Wear personal protective equipment.

WARNING

Toxic liquids

Death or serious personal injury

‐Wear personal protective equipment.

CAUTION

Hot or cold liquid

Minor or moderate personal injury

‐Wear personal protective equipment.

CAUTION

Hot or cold surface

Minor or moderate personal injury

‐Make sure that no one can accidentally come into

contact with hot or cold surfaces.

We recommend that you repair pumps with motors of 7.5 kW and

up at the pump site. Necessary lifting equipment must be available.

1.4 Contaminated products

CAUTION

Biological hazard

Minor or moderate personal injury

‐Flush the pump thoroughly with clean water and rinse

the pump parts in water after dismantling.

The product will be classified as contaminated if it has been used

for a liquid which is injurious to health or toxic. If you request

Grundfos to service the product, contact Grundfos with details

about the pumped liquid before returning the product for service.

Otherwise, Grundfos can refuse to accept the product for service.

Any application for service must include details about the pumped

liquid.

Clean the product in the best possible way before you return it.

Costs of returning the product are to be paid by the customer.

1.5 Servicing the motor

Grundfos MG and MGE motors

Service documentation is available in Grundfos Product Center at

http://product-selection.grundfos.com/.

Motors of other makes

Contact the motor manufacturer.

2. Preparing the dismantling of the product

2.1 Lifting the product

Lifting procedures are described in the installation and operating

instructions. Use the QR code or link below:

http://net.grundfos.com/qr/i/99078486

English (GB)

3. Dismantling and assembling the product

Parts are indicated by numbers and refer to the drawings in the

section on drawings.

Tools are indicated by letters and refer to the section on special

service tools.

Related information

7.3 Special service tools

7.5.1 Overview of drawings

7.5.2 Exploded views

7.5.3 Sectional views

3.1 Motor and coupling

3.1.1 Removal

1. Disconnect the power supply and remove the power cable.

2. Remove screws (7a) and coupling guards (7).

3. Remove screws (9) and coupling halves (10a). It may be

necessary to gently loosen the coupling halves with a plastic

hammer.

4. Remove the cylindrical pin (10) from the pump shaft (51).

5. Attach approved lifting equipment to the motor to prevent it from

falling before proceeding with any further dismantling. For

correct attachment of lifting equipment, see instructions supplied

with the pump.

6. Remove the screws (28), washers (32) and nuts (36).

7. Carefully lift the motor off the pump using approved lifting

equipment. For lifting the motor correctly, see the instructions

supplied with the pump.

3.1.2 Installation

1. Carefully lift the motor onto the motor stool (1a) using approved

lifting equipment.

2. Install the screws (28), washers (32) and nuts (36).

3. Lubricate and tighten the nuts (36) to the specified torque.

4. Install the cylindrical pin (10) in the pump shaft (51).

5. Install the coupling halves (10a).

6. Lubricate and cross-tighten the screws (9).

7. Install the coupling guards (7) and tighten the screws (7a).

Related information

7.1 Torques

7.2 Lubricants

3.2 Shaft seal, motor stool, pump head cover, sleeve

and chamber stack

3.2.1 Preparations

1. Remove the motor as described in the section on motor and

coupling removal.

2. Close the isolating valves, if fitted, to avoid draining the pipe

system.

3. Drain the pump by loosening the vent screw (18) and removing

the plugs (25) and O-rings (38).

Related information

3.1.1 Removal

3.2.2 Dismantling

1. Clean the end of the shaft (51) with a cloth.

2. If the shaft seal (105) is to be reused, remove any marks or

scratches on the shaft (51) by using service tool E together with

a piece of fine emery cloth.

3. Loosen the three set screws (113) of the shaft seal (105). Note

that the set screws must be loosened no more than 1/4 turn.

4. Loosen the shaft seal by using service tool A, together with

service tools O and P.

5. Carefully lift the shaft seal (105) off the shaft (51). Note that the

shaft seals fitted on pumps with ∅28 and ∅36 pump shafts can

be fitted with new wear parts. See the section on renewing shaft

seal wear parts.

6. Attach approved lifting equipment to the motor stool (1a) to

prevent it from falling before proceeding with any further

dismantling.

7. Remove nuts (36) and washers (66a).

8. Remove the motor stool (1a).

9. Remove the pump head cover (2). It may be necessary to

loosen it from the sleeve (55) using a plastic hammer.

10. Remove the O-ring (37) from the pump head cover.

11. Pull out the outlet part (44a) from the pump head cover (2).

12. CR pumps only: Remove the four screws (2d) and the brackets

(2c) from the pump head cover (2).

13. Fit service tool N on the pump sleeve (55). See the figure below.

TM071740

Service tool N fitted on sleeve (55)

14. Attach approved lifting equipment to service tool N and lift the

sleeve (55) up and away from the chamber stack.

English (GB)

15. Fit service tool B in the top of the pump shaft.

When handling the chamber stack, it is important to

pay close attention in order not to damage the thrust-

handling device (120), if fitted.

16. Attach approved lifting equipment to service tool B and lift up the

chamber stack.

TM071900

Lifting the chamber stack

17. Lay down the chamber stack in a fixed position so that it cannot

move.

18. Remove the O-ring (37) from the pump base.

Related information

6. Renewing shaft seal wear parts

7.3.1 Special tools

3.2.3 Assembly

1. Lubricate and install a new O-ring (37) in the pump base (6).

See the section on lubricants.

2. Carefully lift the chamber stack with approved lifting equipment

and lower it into the pump base.

Make sure to align the pump inlet part (44) with the tap in the

pump base (6). See the figure below.

TM071742

Aligning inlet part (44) in pump base (6)

3. Fit service tool N on the pump sleeve (55).

4. Attach approved lifting equipment to service tool N and lift the

sleeve (55) onto the pump base (6).

Make sure to align the sleeve (55) according to the alignment

marks on the sleeve (55) and on the pump base (6). Also

ensure that the sleeve (55) is pressed fully home in the pump

base (6).

TM070849

Aligning sleeve (55) in pump base (6)

5. Lubricate and install a new O-ring (37) in the pump head cover.

See the section on lubricants.

6. CR pumps only: Install the four screws (2d) and the brackets

(2c) in the pump head cover (2). See the section on torques.

7. Install the outlet part (44a) in the pump head cover (2).

English (GB)

8. Install the pump head cover (2) on the sleeve (55). Use service

tool J to centre the chamber stack in the pump head cover (2).

See the figure below.

TM071901

Fitting service tool Jin the pump head cover (2).

Make sure to align the pump head cover (2) according to the

alignment marks on the pump head cover (2) and on the sleeve

(55). See the figure below.

TM071741

Aligning pump head cover (2) and sleeve (55)

9. Attach approved lifting equipment to the motor stool (1a) and lift

the motor stool (1a) onto the pump head cover (2).

10. Install washers (66a) and nuts (36).

11. Lubricate the threads of the staybolts (26) and cross-tighten the

nuts (36) to the specified torque. See the sections on torques

and lubricants.

12. Remove service tool J.

13. Clean and smooth the shaft (51) using service tool E with an

emery cloth supplied with the shaft seal kit.

14. Lubricate the O-rings in the shaft seal (105). See the section on

lubricants.

Avoid lubrication on the seal faces.

15. Install the shaft seal (105) on the shaft (51) and press it home

against the pump head cover (2).

16. Tighten the shaft-seal hexagon nut to the specified torque by

using service tool A, together with service tools O and P. See

the section on torques.

English (GB)

17. Check that the height X is maximum 71 mm. See the figure

below.

If the measured height is not within the specifications, the pump

has not been assembled correctly, and the pump must be

dismantled to find the reason.

TM070969

X: 69 ± 2 mm

Note that the below text applies only for pumps with motor sizes

75 to 200 kW (100-300 hp) and fitted with a thrust-handling

device.

During assembly of the pump, there is a risk that the O-ring

(120i) causes the stationary ring (120g) to stick. As a result, the

entire chamber stack will not be fully seated inside the pump.

This can lead to malfunction and eventually damage to the

pump if it is started. See the figure below.

120g

120i

TM083369

Before making the shaft height adjustment, make sure the shaft

with impellers is placed as much downwards as possible inside

the pump. This can be checked by rotating the shaft by means

of a screwdriver inserted in the cross-hole at the top of the shaft.

TM083256

• If the friction is with high scattering or peaks caused by the

axial metal-to-metal contact between impeller and chamber,

then the shaft with impellers is positioned correctly and you

can go on with the shaft height adjustment using the

adjustment fork.

• If rotating freely with very little friction, try rotating CCW and

CW until the shaft binds and you feel the metallic contact

between the chambers and impellers.

• If you cannot feel the metallic contact between the chambers

and impellers, the pump must be disassembled, and the

stationary ring (120g) must be pressed fully down in the

pump base so that it is seated completely against the lifting

plate (120h) and the flange (120k).

18. Install the cylindrical pin (10) in the pump shaft (51).

19. Install the coupling halves (10a).

20. Lubricate and tighten the screws (9), but leave loose. See the

section on lubricants.

21. Check that the gaps on either side of the coupling halves are

equal. See the figure below.

TM071744

Gap between coupling halves

22. Tighten the three set screws (113) to the specified torque. See

the section on torques.

23. Lift the pump shaft with a crowbar and insert the adjusting fork

F. See the figure below.

TM070868

Lifting pump shaft and fitting adjusting fork.

24. Cross-tighten the screws (9) to the specified torque. See the

section on torques.

English (GB)

25. Pull the adjusting fork F free of the shaft (51) and place it on the

backside of one of the coupling guards (7). See the figure

below.

TM071743

Fitting adjusting fork Fon the backside of coupling guard (7)

26. Install the coupling guards (7) and tighten the screws (7a). See

the section on torques.

Related information

7.1 Torques

7.2 Lubricants

7.3.1 Special tools

3.3 Thrust-handling device

This section applies only for pumps fitted with a thrust-handling

device (120).

All parts for the thrust-handling device must be handled

very carefully in order to avoid damaging them.

There are two ways to service the thrust-handling device:

• by completely dismantling the entire pump.

See instructions in the section on servicing the thrust-handling

device by dismantling the entire pump.

• by positioning the pump horizontally and accessing the thrust-

handling device from the pump base.

See instructions in the section on servicing the thrust-handling

device from the pump base.

Related information

3.3.1 Servicing the thrust-handling device by dismantling the entire

pump

3.3.3 Servicing the thrust-handling device from the pump base

3.3.1 Servicing the thrust-handling device by dismantling the

entire pump

Preparations

Removing the thrust-handling device requires that the pump has

been dismantled as described in the sections on removal of the

motor and coupling and dismantling of the shaft seal, motor stool,

pump head cover, sleeve and chamber stack.

Dismantling

1. Lay down the chamber stack on a solid surface and take the

necessary precautions to prevent the chamber stack from

moving while working on it.

2. Loosen and remove the nut (120f) and washer (120e). Note that

the nut features a left-handed thread. Use service tools C, D, O

and P to hold the shaft when loosening the nut (120f).

D C O P

TM071746

Dismantling thrust-handling device from pump shaft

3. Remove thrust-handling-device wear parts (120a,120b, 120c,

120d). The parts come out together.

4. Remove the stationary ring (120g) together with the lifting plate

(120h) by using service tool G for pulling out the parts.

TM071745

Removing stationary ring (120g) and lifting plate (120h)

5. Remove the bolts (26b) from the pump base (6).

6. Remove the flange (120k) by using two bolts (26b) as

extractors.

26b

TM071747

Extracting the flange

English (GB)

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