Tuthill GlobalGear Series Kurzanleitung

Service Manual 73

Installation and Service

Instructions

GlobalGear Series Pumps

Service Manual 73

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Table of Contents

Introduction Page 2

General Description/Pumping Principle Page 3

Modular Design Page 3

GlobalGear Models Page 4

Installation Page 5

Simple Efficiency Improvement Page 6

Packing Adjustment Page 6

Lubrication Requirements Page 7

Recommended Lubricants Page 7

Parts Interchangeability Page 8

Inspection / Repair Page 9

Pump Disassembly -Partial Page 9

Drive Module Remova ;Page 10

Drive Module Installation Page 11

Cover / Idler Gear Installation Page 12

Relief Valve Installation Page 12

In-Line Seal / Packing Replacement Page 13

Torque requirements-Mounting hardware Page 13

Pump Disassembly –Complete Page 17

Pump Assembly Page 20

Idler Bushing Installation Page 20

Bracket Bushing Installation Page 21

Packing Installation Page 22

In-Board Mechanical Seal Installation Page 23

Out-Board Mechanical Seal Installation Page 23

Drive Module Rebuild / Installation Page 25

Cover / Idler Gear Installation Page 26

Relief Valve Installation Page 26

End Clearance Adjustment Page 27

Relief Valve Disassembly Page 29

Relief Valve Assembly Page 29

Pressure Adjustment of Relief Valve Page 29

Troubleshooting Page 30

Material Returns Page 32

Introduction

The GG Series pumps have been designed and manufactured to provide years of service under

normal operating conditions.

Illustrations used in this manual are for reference purposes only. Consult the factory or an

authorized Tuthill distributor for proper part identification.

When ordering replacement parts, provide as much detail as possible to ensure correct parts are

provided. Details should include the full model number (18 digits), serial number, name of part,

part number (if known) and part material.

Service Manual # 73 for the GG Series pumps is available at www.tuthillpump.com

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General Description

The GG Series pumps use the internal gear design pumping principle (see Figure 1) to perform

the positive-displacement pumping action desired. Thus, the pump has only two moving parts,

the rotor and idler gear.

Figure 1 –Internal Gear Pumping Principle

Pumping action is based on a rotor, idler gear and crescent-shaped partition cast integral with the

cover.

Power applied to the rotor is transmitted to the idler gear with which it meshes. The space

between the outside diameter of the idler and the inside diameter of the rotor is sealed by the

crescent.

As the pump starts, the teeth come out of mesh, increasing the volume. This creates a partial

vacuum, drawing the liquid into the pump through the suction port.

The liquid fills the spaces between the teeth of the idler and the rotor and is carried past the

crescent partition through the pressure side of the pump.

When the teeth mesh on the pressure side, the liquid is forced from the spaces and out through

the discharge port.

The materials furnished for each pump are selected to suit individual applications.

Modular Design

The GG Series of pumps have a Modular Design concept. This allows for simplified maintenance

of the pump and a broad range of flexibility on the design. For more information, consult the GG

Series Catalog or your authorized Tuthill distributor.

The GG Series of pumps allows for simplified repairs.

Back-Pullout—This allows the Drive Module ( rotor/bracket/bearing carrier/bearing caps

assembly) to be removed from the pump housing without disturbing the piping attachments. This

requires the use of a spacer coupling.

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In-Line Seal replacement--- This allows for the replacement of the seals/packings without

completely disassembling the pump.

The GG series of pumps have bolt-on ports when furnished with a housing with a 90°porting

arrangement.. This allows a broad range of flexibility for porting options in both size and

configuration.

GlobalGear Models

The models of the GG series of pump are shown in Table 1 below.

Material of max capacity max pressure

Construction size max

speed USGPM LPM PSI BAR

GG015 1800 15 57 200 13.8

GG030 1800 30 114 200 13.8

GG050 1500 50 189 200 13.8

GG070 1500 70 265 200 13.8

cast iron GG080 1500 80 303 200 13.8

GG090 1500 90 341 200 13.8

GG120 1200 120 454 200 13.8

GG130 1000 130 492 200 13.8

GG200 1000 200 757 200 13.8

GG210 800 210 795 200 13.8

GG015 1200 10 38 150 10.3

GG030 1200 20 75 150 10.3

GG050 1000 33 125 150 10.3

GG070 1000 46 174 150 10.3

Stainless steel GG080 1000 53 200 150 10.3

GG090 1000 60 227 150 10.3

GG120 800 80 303 150 10.3

GG130 640 86 325 150 10.3

GG200 640 133 503 150 10.3

GG210 500 140 530 150 10.3

Table 1 –GlobalGear Models

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!WARNING

Failure to follow these instructions could result in serious bodily injury or death.

Do not attempt to work on any Tuthill pump installation before completing the steps below.

Disconnect the drive so that it cannot be started while work is being performed.

Review the Material Safety Data Sheet (MSDS) applicable to the liquid being pumped to

determine its characteristics and the precautions necessary to ensure safe handling.

Vent all pressure within the pump through the suction or discharge lines.

All Tuthill pumps contain residual hydraulic oil from the factory production test. Determine if this is

compatible with the fluid you are pumping. If the fluid is incompatible, then the pump must be

fully flushed prior to use.

If the pump is to be operated at elevated temperatures, the pump should be brought up to

operating temperatures gradually. Rapid or sudden introduction of liquids at elevated

temperatures into the cold liquid chamber of the pump could cause damage to pump externals,

seals or other internal parts.

Do not run the pump dry. Failure to comply with this could cause severe damage to the internal

seal, bushings and/or metal parts.

Installation

For optimum pump performance the suction line must be at least as large as the corresponding

pump port. It should be as short as possible in order to avoid excessive pressure drops and must

be airtight. Locate the pump as close to the source of supply as conditions permit and if possible,

below the level of the liquid in the reservoir. When necessary to locate the pump in a pit,

provisions should be made to safeguard against flooding.

When handling high viscosity liquids, the speed of the pump must be reduced and the size of the

inlet lines increased to prevent cavitation. Refer to the NPSHr data for the pump. The GlobalGear

series of pumps provides a orifice vent to the seal chamber in the bracket from one of the

housing’s ports ( typically the suction port). On applications where the viscosity is 7500 SSU or

greater, the orifice plug should be removed so there is no restriction on the vent hole.

Pumps should be filled with liquid at installation and should never be allowed to run dry.

The placement of a strainer on the suction side of the pump will restrict any solids or abrasives

from entering the pump, which could cause internal damage.

Under no conditions should the pump be used to support external piping loads (weight or

expansion). Piping and other equipment should be independently supported. Piping strain can

result in misalignment, hot bearings, worn couplings, vibration, etc. It is important that the piping

used be clean and free of chips and scales.

The discharge line must be designed with the maximum pressure rating of the pump in mind.

Excessive pressure could cause damage to your motor and/or pump. If a pressure relief valve

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has not been supplied with the pump, some other means of pressure protection must be utilized.

This could include in-line safety valves, pressure shutdown switches or other similar devices.

Pumps shipped from the factory with relief valves have the relief valve set at full by-pass at the

factory on 150SSU oil at our factory production test speeds. Field adjustments will be required to

meet the actual application requirements.

Pumps shipped from the factory with relief valves are assembled for clockwise or

counterclockwise rotation as originally specified. If you want to change rotation, the relief valve

assembly must be removed and turned 180 degrees. The adjusting screw must always point

toward the suction line.

Every pump installation should have a good foundation. Its structure should be sufficiently strong

to hold the pump rigid and to absorb any strain or shock that may be encountered. The

installation should be leveled, checked for proper piping alignment, and then fastened securely.

The alignment should be rechecked after the pump’s temperature has reached it’s operating

temperature.

Direct drive through a traditional flexible coupling is recommended. However, do not expect the

coupling to compensate for misalignment. Contact the coupling manufacturer to determine the

maximum amount of misalignment that the coupling can be subjected to.

Never operate the pumps without all the guards in place.

Pumps operating with bi-directional rotation must have pressure relief devices installed on both

sides of the pump.

Simple Efficiency Improvement

The efficiency of the pump may decrease after considerable use as a result of wear. If

performance deteriorates below acceptable levels, it may be moderately improved by reducing

the end clearance between rotating elements. Refer to the appropriate reassembly instruction to

accomplish this task. If this does not improve performance to an acceptable level, then further

repair work may be necessary.

Packing Adjustment

!WARNING

Packing is designed to leak. Therefore, when pumping hazardous liquids, a mechanical seal is

recommended to minimize any potential source of leakage that could result in a hazardous

condition.

Pumps with packing will require periodic adjustment.

To accomplish this, gently and evenly tighten the packing gland nuts, which will further compress

the packing.

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Do not over-tighten. Packing is designed to keep leakage to a slight weep. Normally 2-3 drops

per minute is acceptable.

If excessive leakage persists after complete adjustment, consider re-packing the stuffing box or

using another packing type.

Lubrication Requirements

Outer Bearing

The standard outer bearings are maintenance-free. They are greased and sealed by the

manufacturer.

Optional high temperature outer bearings must be re-lubricated at least every 250 hours or 30

days.

Bracket Bushing

Bracket bushings that do not have grease fittings are fully lubricated by the pumped fluid and are

maintenance-free.

Bracket bushings that are provided with grease fittings must be re-lubricated at least every 500

hours or 60 days.

Idler Bushing

Idler bushings that are used with standard solid idler pins are fully lubricated by the pumped fluid

and are maintenance-free.

Idler bushings that are used with optional greasable idler pins must be re-lubricated at least every

500 hours or 60 days.

Recommended Lubricants

Recommended Temperature Range

Minimum Maximum

Description

Manufacturer Grade

Deg. F Deg. C Deg. F Deg. C

Lubriplate 1200-2-25 -32 350 177standard

grease Mobil Mobilith AW 2 -25 -32 350 177

Lubriplate HIGH-TEMP 40 4500 260

Lubriplate 930-AA 0-18 400 204

high

temperature

greaseMobil Mobilith SHC PM 0-18 450 232

Lubriplate MAG-1-60 -51 200 93low temp.

grease Mobil Mobiltemp SHC 32 -60 -51 200 93

Lubriplate FGL-210 -12 350 177food grade

grease Mobil Mobilgrease FM 102 10 -12 350 177

NOTE: This lubrication data is only intended as a guide. Some applications may have different

lubrication requirements, depending on actual conditions.

Table 2 –Recommended Lubricants

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Parts Interchangeability

Idler Bushing

Cover

Idler

Rotor/Shaft Assembly

Ports

Bearing Carrier

Bearing Caps

Ball Bearing

Gland

Foot Seal

Relief Valve Assembly

Housing

PART NAME GG015 GG030 GG050 GG070 GG080 GG090 GG120 GG130 GG200 GG210

RELIEF VALVE ASSEMBLY

HOUSING

PORTS

BRACKET / BUSHING ASSEMBLY

BRACKET BUSHING

COVER / PIN ASSEMBLY

IDLER / BUSHING ASSEMBLY

IDLER BUSHING

ROTOR / SHAFT ASSEMBLY

MECHANICAL SEAL OR PACKING

GLANDS

BEARING CARRIER

INNER BEARING CAP

OUTER BEARING CAP

BALL BEARING

FOOT (see note)

PUMP SIZE

Figure 2

Note: Pumps with 180°ports have a housing with a cast integral foot. These do not include a

separate foot.

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Inspection / Repair

Should it be necessary to remove the pump from service for periodic inspection of components

and/or a major repair, the following steps should be taken.

!WARNING

Failure to follow these instructions could result in serious bodily injury or death.

Do not attempt to work on any Tuthill pump installation before completing the steps below.

Only authorized personnel who are familiar with the repair of mechanical products should perform

the necessary repair work. You must familiarize yourself with the entire contents of this manual

prior to performing any work

Disconnect the drive so that it cannot be started while work is being performed.

Review the Material Safety Data Sheet (MSDS) applicable to the liquid being pumped to

determine its characteristics and the precautions necessary to ensure safe handling.

Vent all pressure within the pump through the suction or discharge lines.

Ensure that the pump has cooled a safe temperature prior to performing any work on the pump.

Pump Disassembly -Partial

The GG Series of pumps provides the ability to rebuild the internal pumping components of the

pump without removing the pump housing from the baseplate. This is accomplished by removing

the cover and idler gear from the front end of the pump and the drive module from the shaft end

of the pump.

REMOVING THE COVER AND IDLER GEAR

REMOVE PUMP COVER:

Note: On pumps with relief valves on the cover, the cover can be removed with the relief

valve still mounted onto the cover.

IF NECESSARY, REMOVE SAFETY RELIEF VALVE:

If the pump has a safety relief valve mounted on it, remove it by loosening the bolts that

mount it to the cover or housing.

Prior to removing the cover, the general position should be marked in relationship to the

housing. Once done, remove the cover bolts and the cover.

!WARNING

When removing the cover, the idler gear will generally stay on the pin. Avoid tilting the cover

downward as the idler may slide off, causing injury or damage.

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REMOVE THE COVER GASKET:

If a new gasket is not available, reuse of the original gasket is acceptable, provided it is not

torn or otherwise damaged.

REMOVE THE IDLER FROM THE PIN:

With the idler gear still on the cover, check for excessive wear between:

−the pin and bushing,

−the idler and cover crescent,

−idler width and crescent height.

Any visible signs of excessive wear will require replacement of the cover/pin assembly

and/or the idler and the bushing.

If only the bushing shows signs of minor wear, it should be replaced. Acceptable bushing

clearances are shown in Table 3 (for pumps with standard clearance only)

Acceptable Clearance

Pump Size inch mm

GG015 0.001 -0.007 0.038 -0.178

GG030 0.001 -0.007 0.038 -0.178

GG050 0.002 -0.008 0.051 -0.203

GG070 0.002 -0.008 0.051 -0.203

GG080 0.002 -0.008 0.051 -0.203

GG090 0.002 -0.008 0.051 -0.203

GG1200.002 -0.009 0.064 -0.229

GG130 0.002 -0.009 0.064 -0.229

GG200 0.003 -0.009 0.089 -0.229

GG210 0.003 -0.009 0.089 -0.229

Table 3 -Idler Bushing Clearances

Note: Many Tuthill pumps are provided with non-standard clearances for use with high-

viscosity or high-temperature fluids. Consult the factory for clearances of these pumps.

Drive Module Removal

REMOVE THE DRIVE MODULE ASSEMBLY FROM HOUSING:

If service is being completed with the housing still mounted to the baseplate/piping, you must first

remove the spacer from the spacer coupling.

Adequately support the housing ( on the cover side) so it will not fall.

Remove the bolts that hold the bracket to the housing.

On pumps that do not have a cast integral foot, remove the bolts that attach the foot to the

bearing carrier.

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