Berkeley Ownwes Manual
Berkeley Ownwes Manual
Berkeley Ownwes Manual
IMPORTANT
For best possible performance and continuous, satisfactory operation, read these instructions before installing your new pump. Should service be required, this manual can be a valuable guide. It should be kept near the installation for ready reference. Record nameplate data from pump on blank nameplate inside this manual for future reference.
Table of Contents
SAFETY ...................................................................................................................................3 INSTALLATION
General Information ......................................................................................................3,4,5 Flywheel Coupling ...........................................................................................................6,7 Pump to Engine Assembly..................................................................................................8 Verify Rotation ....................................................................................................................9 Suction Connection .....................................................................................................10,11 Discharge Connection .................................................................................................12,13
START-UP
Priming ........................................................................................................................14,15 Operation ..........................................................................................................................15
MAINTENANCE
General Information ..........................................................................................................16 Packing Ring Replacement ..............................................................................................17 Impeller Removal..............................................................................................................18 Seal/Impeller Replacement ..............................................................................................19 Shaft Maintenance/Replacement .....................................................................................20 General Pump Care..........................................................................................................21 Routine Inspection Check List ..........................................................................................22
PUMP NOMENCLATURE
General Information ..........................................................................................................23 Parts Breakdown .........................................................................................................24,25
TROUBLESHOOTING
Chart.................................................................................................................................26
Page 2
F00636
Safety First
General Information
READ AND FOLLOW SAFETY INSTRUCTIONS!
This is the safety alert symbol. When you see this symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury: DANGER warns about hazards that will cause serious personal injury, death or major property damage if ignored. WARNING warns about hazards that will or can cause serious personal injury, death or major property damage if ignored. CAUTION warns about hazards that will or can cause minor personal injury or property damage if ignored. The label NOTICE indicates special instructions which are important but not related to hazards. Carefully read and follow all safety instructions in this manual and on pump. Keep safety labels in good condition. Replace missing or damaged safety labels.
WARNING
Rotating parts. Can catch hands, feet, or clothing. Stay clear of equipment and keep shields in place while pump is running. Stop motor or engine before servicing pump. Read owners manual before using equipment.
General Safety
Do not allow pump, piping, or any other system component containing water to freeze. Freezing may damage system, leading to injury or flooding. Allowing pump or system components to freeze will void warranty. Pump approved liquids only with this pump. Periodically inspect pump and system components. Wear safety glasses at all times when working on pumps. Keep work area clean, uncluttered and properly lighted; store properly all unused tools and equipment. Keep visitors at a safe distance from the work areas.
F00636
Page 3
Installation
General Information
NPSHR
NPSHR at this point = 10 Feet NPSHR at this point = 14 Feet
EXAMPLE ONLY
B3ZQM 30 NPSH in Feet 20 10
NPSHA
8.5 Feet total friction loss @ 500 Gallons per minute. 9.5 Feet total friction loss @ 600 Gallons per minute.
200
500 GPM Static Lift = 7.0 Feet Total Friction Loss = 8.5 Feet Total = 15.5 Feet
TDH
50
100
200
300
700
800
900
Theoretical static lift of centrifugal pump at sea level = 34.0 Feet Safety Factor - 6.0 Feet Practical Limit = 28.0 Feet Minus 15.5 Feet OK NPSHA = 12.5 Feet 28.0 Feet 16.5 Feet
A Model B3ZQM operating at 500 GPM with 80 Feet of Head has a NPSHR of.......... 10 Feet at that point on the performance curve. A Model B3ZQM operating at 600 GPM with 68 Feet of Head has a NPSHR of.......... 14 Feet at that point on the performance curve.
CAVITATION
6044 0609
Figure 1
LOCATION
Locate the pump as near the water source as practical. Make pipe run short, straight and with as few pipe fittings as possible, to keep total friction loss to a minimum. Install pump in a clean, dry and drained location if possible and protect against moisture and adverse weather conditions. Pump should be located on a level, hard surface to prevent shifting or tipping. Locate to be readily accessible for inspection and maintenance. Because of the portable nature of this style pump, careful attention should be taken to assure that Net Positive Suction Head Available (NPSHA) exceeds Net Positive Suction Head Required (NPSHR) by the pump or reduced performance and severe pump damage may result. Figure 1, illustrates where these terms (NPSHA / NPSHR) come from, and how to determine if the pumping conditions at which you want to operate meet the proper criteria. When in doubt, consult your nearest Berkeley Professional Dealer. NOTE: If pump site is 1000 feet above sea level, subtract 1.2 feet from the NPSHA equation and an additional 1.2 feet for each additional 1000 feet of elevation.
Portable Installation: Pump should be placed on an area that will provide a solid foundation substantial enough to support the weight of pump and engine and also to provide stability while the pump is running. Engine vibration will cause shifting on any type of loose surface and cause piping strains and possible damage. NOTICE: Settling and/or shifting during operation can cause piping to place excessive strain on the pump and may damage pump case. Permanent Installation: Pump and Engine should be set on a concrete foundation which is sufficiently substantial to absorb vibration and which will provide a permanent and rigid support. Bolt engine directly to concrete.
PIPING
System piping should be at least one commercial pipe size larger than pump connections and flow velocity should not exceed eight (8) feet per second. Misalignment of piping with pump case or excessive pipe strain can cause distortion of pump components resulting in rubbing, breakage and reduced pump life. Insure that piping is supported in a manner that prevents the exertion of force on pump connections. If ANSI type flange connections are used, this can be checked by the following procedure. With the pump shut down, remove pipe flange bolts. If the mating flanges come apart or shift, misalignment is present and causing pressure on the connections. Adjust pipe supports until flanges mate without any force. This procedure can be done throughout piping system. F00636
PUMP FOUNDATION
CRUSHING WEIGHT. Models with larger suction and discharge openings are extremely heavy. Use care and proper equipment when handling pump for installation. Be sure to allow for the weight of the water in the pump and piping.
Page 4
Installation
General Information
Flywheel Housing Dimensions A B No. C Size TABLE 1 S.A.E. Flywheel Housing Size 1 20-1/8 20-7/8 12 7/16-14 2 17-5/8 18-3/8 12 3/8-16 3 16-1/8 16-7/8 12 3/8-16 4 14-1/4 15 12 3/8-16 5 12-3/8 13-1/8 8 3/8-16
C ENGINE
Figure 2
SUCTION PIPING
Refer to illustrations on Page 10 and 11 for recommended and not recommended practices in suction connections.
DISCHARGE PIPING
Refer to illustrations on Page 12 and 13 for recommended and not recommended practices in discharge connections.
and/or the air temperature increases. When driving the pump at the RPM required to deliver water into the system piping, the engine must operate within the engine manufacturers minimum and maximum RPM limits. The power output to supply the pump power demand must not exceed the CONTINUOUS POWER RATING of the engine, after derating for all power consuming engine accessories, and adjustment for installation site altitude and air temperature. Proper power matching of the pump and engine is the responsibility of the pump and engine unit assembler.
Page 5
Installation
Flywheel Couplings
FLYWHEEL COUPLING
The flywheel coupling transmits power from the engine flywheel to the pump shaft. The maximum power that a coupling can safely handle is shown by a rating number, R, which is listed in the coupling dimensions tables. When selecting a flywheel coupling for a pump and engine, first determine the power rating that the pump will demand. On the pump performance curve, find the RPM and BHP values required to produce the application head-capacity point. Divide the BHP by the RPM, then multiply the result times 100. The result will be the demand number for the pump. For example, a B6JQBM can deliver 1500 GPM at 260 feet Total Head when running at 2200 RPM. The power required by the pump will be 120 BHP. The demand number will be: (120/2200) x 100 = 5.45 Next, select a coupling that can safely transmit the power, and which will fit the flywheel dimensions. For a coupling to be suitable, it must have an R rating number GREATER THAN the pump demand number. In the above example, the minimum coupling R number would be 6. NOTE: The isolator disc design of Berkeley flywheel couplings provides smooth power flow from the engine to the pump, and torsional vibration problems are rare. However, with the broad range of engines available, a torsional mismatch can occur, which can cause excessive stress in the pump shaft and coupling. Torsional compatibility of the engine, pump, and coupling is the responsibility of the assembler. Berkeley Pumps will supply data for the pump and coupling for use by the assembler for a torsional analysis. NOTE: If the flywheel is fitted with a pilot bearing pressed into a bore at the center, remove it to avoid interference with the pump shaft.
OTHER FLYWHEELS
Some engines are fitted with flywheels especially machined for coupling to other kinds of machinery (electrical generators, torque converters, etc.), and require nonstandard flywheel couplings. If the measured flywheel dimensions do not correspond to dimensions listed in Tables IIa or IIb, write the measured dimensions into the Dimension Form provided on page 23, and send it to Berkeley for quotation of special flywheel coupling.
Page 6
F00636
Installation
Flywheel Couplings
H G Engine D
Flywheel Coupling
Spline Diameter
BC F E BC
-10T (Spline Count)
Figure 3
F00636
Page 7
Installation
NOTE: When the coupling is correctly assembled, the hub will not bottom out on the shaft splines. If it should bottom out, reverse the coupling on the shaft as shown to gain clearance.
Pump Bracket
Engine
Pump Bracket
Preferred Installation
B
A
Alternate Installation
4021 0801
Figure 4
Figure 5
Page 8
F00636
Installation
kwise rotatio oc n Cl
If Engine fan is rotating clockwise as viewed, a pump with clockwise rotation is required.
View-"A"
View-"B"
DIESEL ENGINE
View-"B" looking toward pump shaft. Pump volute indicates clockwise rotation as viewed from driver as shown.
6046 0609
Before pump is put into operation, rotational direction must be verified to assure proper performance of pump. Standard engine rotation is clockwise.
Pump running backward: Centrifugal pumps will still pump liquids, however, GPM and head will be a fraction of the published performance. Threaded impellers may loosen.
F00636
Page 9
Installation
Suction Connection
Portable and Permanent
Portable Installation is most common with this style pump.
Connection for optional Engine Exhaust Primer. Locate at least one (1) pipe diameter from pump case. Eccentric Reducer flat side up.
Companion Flange Kit Short length of straight pipe. (2 times pipe diameter)
Slope upward to pump. Companion Flange Kits NOTICE: All connections must be air tight.
Suction Gauge
Straight run, short as possible but at least 6 times pipe diameter ("D") after elbow to stabilize flow.
As close as possible
Recommendations called out in field of drawing apply to both suction connections shown. Use pipe, tubing or reinforced hose to make suction connection. Hose must have sufficient strength to resist collapse under pressure differential that occurs while pump is running. Suction pipe size should be at least one commercial pipe size larger that opening in pump inlet. Flow velocity should not exceed 8 ft./sec. Suction screen area must be at least four times suction pipe area. Net Positive Suction Head Available (NPSHA) must exceed Net Positive Suction Head Required (NPSHR) by the pump or reduced performance and severe pump damage may result. All suction piping must have a continuous rise to the pump suction inlet. For rigid pipe or tubing, a 1/4 inch per foot minimum slope is recommended.
Strainer / Foot Valve To keep debris from entering pump suction and to maintain pump prime after shut-off.
Recommended
Page 10 F00636
Installation
Suction Connection
Portable and Permanent
Avoid suction hose that may collapse during operation due to insufficient strength. High spot in suction hose may result in air pocket.
Concentric Reducer causes high spots along the suction line resulting in air pockets.
No support or uneven mounting not recommended. Long run not recommended Excess use of pipe fittings means potential air leaks.
Callouts in field of drawing apply to both suction connections shown. Elbow immediately in front of pump intake not recommended. Suction pipe sloping downward to pump inlet will trap air which will reduce performance and may cause pump to lose prime. Suction piping that is undersized will create excess friction losses that may cause cavitation and a reduction in pump performance. Excess fittings and bends in suction line results in trapped air, reduced performance, and high friction losses which may cause cavitation.
Not Recommended
F00636 Page 11
Installation
Discharge Connection
Expansion joint with tie rods. Non-Slam or spring loaded check valve.
6049 0609
Use pipe, tubing or reinforced hose to make discharge connection. Hose must have sufficient strength to contain the pump discharge pressure. Discharge pipe diameter should be at least one nominal pipe size larger than discharge opening in pump and sized so that flow velocity is below 8 ft./sec. Use only non-slamming check valves to prevent hydraulic shock (water hammer).
Use gate, ball or butterfly valve for isolation. Valve should be full open during operation. Maintain proper size throughout discharge system, using as few elbows and tees as possible to keep friction loss to a minimum. Install pressure gauge after reducer to check operating pressure.
Recommended
Page 12 F00636
Installation
Discharge Connection
Do not use Gate Valve to throttle flow. Avoid abrupt change in pipe size.
6050 0609
Avoid excess friction loss caused by numerous fittings, insufficient pipe diameter, and sharp turns in pipe run. Some swing type check valves may permit buildup of reverse velocity before closing, causing hydraulic shock (water hammer). Do not force pipe alignment that can cause flange stress.
Not Recommended
F00636 Page 13
Start-Up
Pump Priming
Hand Primer
6051 0609
Page 14
F00636
Start-Up
Pump Priming
PRIMING
Pump priming is the displacement of air with water in the pump and suction piping. Pump MUST BE completely filled with water when operating. Refer to Page 14 for instruction on the following conditions: 1. Suction lift with priming pump (water source below pump). 2. Suction lift with exhaust primer (water source below pump). 3. Suction lift with foot valve (water source below pump). 4. Flooded suction (water source above pump, or incoming water pressure is greater than atmospheric pressure). Special Case Hydraulically Balanced Pumps Packed Pumps: Hydraulically balanced pumps operate at a very low positive pressure across the stuffing box, permitting a much looser fit of the packing rings around the shaft sleeve to control the loss of water from the pump through the stuffing box. Because of the looser fit of the packing rings, air can be more easily drawn into the pump through the stuffing box when priming the pump with an air evacuation type primer. A grease fitting, communicating through the side of the stuffing box to a lantern ring in the packing set, is provided to grease-seal the stuffing box to prevent air leakage during priming. If pump cannot be primed due to air leakage through stuffing box, DO NOT tighten packing. Instead, pump NLGI No. 4 Water Pump Grease into lantern ring until back pressure occurs forcing grease into the lantern ring, grease sealing the stuffing box. After priming, when unit is put into operation, the grease will be flushed out through the packing by the water flowing outward through the stuffing box. Proceed with normal adjustment of the packing as described on Page 17. Note that the grease seal only is used for control of air leaking during priming, and that only the packing gland is used to control the flow of water the stuffing box during normal operation. When necessary to replenish the grease supply, use an NLGI No. 4 Water Pump Grease. Mechanically Sealed Pumps: Mechanically sealed pumps require no special procedures unless they are mounted vertically. In this case, call Berkeley Customer Service at 1-888-237-5353 for more information.
STARTING
Never run pump dry. Running pump without water will overheat pump and damage internal parts. Always make sure pump is primed prior to start-up. Engine Operation Refer to engine owner/operator manual supplied with pump for starting and operating instructions. Pump performance varies depending on engine RPM. Refer to engine operators manual to adjust engine speed. Risk of Engine Damage. Operating pump at lower than rated head can cause excessive load on engine. In addition, pump has the capability of overloading engine if allowed to run continuously at an RPM or flow rate that is above specified hydraulic performance. Risk of pump damage. Operate the engine in its preferred RPM range. Reduced RPM for long periods may damage the pump liquid end. Pump Operation Prime pump by one of the previous described procedures. Start engine. Slowly open discharge valve until desired flow rate is achieved, or pump is operating against head for which it was selected. After pump is running, allow packing to leak liberally for a few moments. Then tighten gland nuts one complete turn each until leakage is reduced to 40 to 60 drops a minute. If pump is equipped with a rotary mechanical seal, no adjustment is necessary. Shutting Down Close discharge valve to hold prime before stopping pump. Valve should remain closed until pump/engine is restarted. Reduce the engine RPM prior to shutting down to reduce hydraulic shock (water hammer).
F00636
Page 15
Maintenance
General Information
LUBRICATION
LIQUID END of pump requires no lubrication. Wear rings, packing rings, and models using a mechanical shaft seal, are lubricated by the liquid being pumped. Do Not Run Dry! BRACKET: Add approximately 2 oz. of a lithium-based NLGI No. 2 extra pressure ball bearing grease to each bearing during quarterly inspection. Refer to pump parts drawing on Page 24, grease fittings are labeled with a circled L. Excessive grease will cause bearings to run hot. NOTE: Grease fitting in packing area is for priming only. See Priming in start-up section for instruction. The following brands of bearing grease are factory approved by Berkeley Pumps and are recommended for use in maintenance operations. Shell Brand Alvania Grease EP2 Mobil Oil brand Mobilith AW#2 Exxon Ronex MP Atlantic Richfield Litholine EP2 Amoco Amolith EP2 ENGINE: Refer to engine manufacturers operating manual for complete maintenance instructions. of time, the surface of the pump bracket near the bearings will be quite warm (as high as 150 F), which is normal. If the surface temperature of the pump bracket or engine is excessive, discontinue operation, determine cause of temperature rise, and correct. Bearings will run hotter for a brief run-in period after packing, which is normal. However, worn bearings will cause excessive temperatures and need to be replaced. The pump unit is cooled by the water flowing thorough it, and will normally be at the temperature of the water being pumped. STUFFING BOX. After a short period of operation, verify that the stuffing box area and gland are not hot. If heating is detected, loosen the gland nuts evenly until water is just running out of stuffing box in DROPLET form (40 to 60 drops per minute). Water must not be streaming or spraying out. Verify cool operation periodically. Adjust gland nuts EVENLY as necessary for lubrication and cooling of the packing. If packing has been tightened to the limit of the packing travel, additional packing is necessary.
REPACKING
Refer to illustration on Page 17.
MECHANICAL SEAL
Adjustment or maintenance is not required. The seal is enclosed within the pump and is self-adjusting. Seal is cooled and lubricated by the liquid being pumped.
PERFORMANCE CHECK
Periodically check the output of the pump. If performance is noticeably reduced, refer to Troubleshooting Chart.
OBSERVATIONAL MAINTENANCE
When the pump and system operation have been stabilized, verify that pump unit is operating properly. Observe the following: VIBRATION: All rotating machines can be expected to produce some vibration, however, excessive vibration can reduce the life of the unit. If the vibration seems excessive, discontinue operation, determine cause, and correct. NOISE: When the unit is operating under load, listen closely for unusual sounds that might indicate that the unit is in distress. Determine the cause and correct. OPERATING TEMPERATURE: During operation, heat is dissipated from the pump and the driver. After a short period
Page 16
F00636
Maintenance
Packing Gland
Packing Hooks
Packing Ring
Shaft
Shaft
1
Unfasten hardware holding packing gland in place and slide back on shaft to expose packing rings. A split packing gland with threaded studs is shown. Remove packing rings from stuffing box using two commercially available packing hooks as shown.
2
6052 0609
Slide lantern ring (if used) back to expose any remaining rings, including metallic. Remove them in the same manner.
Packing Rings
Pump liquid end removed for pictorial clarity only. Remove packing gland and packing rings through frame B cutout.
ER KE LE Y
Shaft
6053 0609
Clean shaft sleeve and packing gland. Inspect shaft sleeve for wear, replace if needed. Install new packing rings in stuffing box by placing over shaft sleeve and pushing them in as far as they will go. Rotate ring joint 90 degrees when installing each ring as shown.
Slide packing gland into position (gland must enter stuffing box bore) then gently and evenly tighten nuts to force rings into place and seat (do not over tighten). Loosen nuts again to hand tight. Start primed pump and allow packing to leak liberally. While pump is running, evenly tighten gland nuts one complete turn at a time until leakage is reduced to droplet form (40 to 60 drops per minute).
F00636
Page 17
Maintenance
Impeller Removal
6054 0609
1. Remove the volute and the old gasket(s) and O-Ring(s). Discard the gaskets and O-rings. Check the clearance between the impeller hub and the volute wear ring. If it is more than .020 on a side, replace the wear ring.
NOTE: Certain models, such as the B4EY, have a suction cover which is removed first to gain access to the impeller. On these models, remove the access cover, then remove the impeller (see below), and then remove the seal from the volute.
BE
RK
EL
EY
Note: A hexnut placed between the jackscrew and shaft end will prevent damage to the shaft and impeller screw threads.
2. Remove the impeller: A. Pull keyed impellers off the shaft with a standard gear puller against the end of the shaft and pulling on the impeller. NOTE: Place the pullers fingers against the vanes in the impeller. Pulling on the impellers unsupported back shroud could easily break the impeller. Page 18
B. Unscrew threaded impellers. NOTE: Pumps with clockwise rotation as viewed from the shaft (engine) end have a right-hand threaded impeller. Pumps with counterclockwise rotation as viewed from the shaft (engine) end have a left-hand threaded impeller. The impeller cap screw is always right-hand thread.
RE M
OV E
6055 0609
F00636
Maintenance
Seal/Impeller Replacement
1
B4EY Series Seal Change Sequence
A
2
3
Remove seal plate
C
6056 0609
3.
4.
If your pump has a bolted in balance ring, remove it; if it has a pressed in balance ring, leave it in place unless there isnt room to get the seal out past it. If it doesnt have a balance ring, go to Step 4. Check the clearance between the balance ring and the impeller hub. If it is more than .020 on a side, replace the balance ring. Remove the seal retaining ring and pull the rotating part of the seal off the shaft.
9.
Compress the seal spring on the shaft sleeve and reinstall the seal retaining ring (if used). 10. Reinstall the balance ring (if used). 11. Slide or thread the impeller onto the shaft until it seats solidly against the shaft shoulder, then install a new impeller screw with its associated hardware. 12. Replace the volute. Use new gasket(s) and O-Ring(s). B4EYQBHS and similar pumps (See Picture Above): After STEP 4, you will need to: A. Remove the bracket from the engine. B. Remove the outer bearing cap and slide the shaft assembly back out of the bracket. C. Remove the seal retainer and tap out the stationary seal. D. Clean the seal retainer and shaft (dont scratch the shaft!). E. Apply a small amount of mineral oil to the O-Ring or cup seat of the stationary seal, to the inside diameter of the rubber ring in the rotating seal, and to the outside of the shaft sleeve. F. Use the cardboard washer (supplied) and a piece of pipe to press the stationary seal into place. G. Inspect the oil seal and replace it if necessary. H. Repack the bearings and reinstall the shaft in the bracket. NOTE: When the end of the shaft comes through the front bearing bore in the bracket, slip the slinger and seal retainer over the end of the shaft. BE SURE you dont damage the seal face on the shaft shoulder! J. Reinstall the outer bearing cap with a new gasket and proceed to STEP 7 (Reinstall the shaft sleeve....)
Model B4EYQBHS and similar pumps: See the special section on this page. Others: go to Step 5. 5. Z Series: Pull the seal plate out until it clears the shaft, bringing the stationary part of the seal out with it. Tap the seal out of the seal plate and clean the seal cavity. Other Pumps: Pull the stationary part of the seal out of the cavity and clean the cavity. 6. Install the new stationary seal in the seal cavity. Apply a small amount of mineral oil to the O-Ring or cup seat of the stationary seal. Use the cardboard washer (supplied) and a piece of pipe as a press; press the stationary seal into place. Do not damage the seal face! 7. Reinstall the seal plate (if used) now. Cover all shaft threads with tape to protect the seal during installation. Apply a small amount of mineral oil to the inside diameter of the rubber ring in the rotating seal and to the outside of the shaft sleeve. Slide the seal plate over the shaft now, taking care to avoid damage to the stationary part of the shaft seal as it goes over the shaft shoulder. 8. After lubricating the rotating part of the seal, slide it onto the shaft and sleeve until it seats against the stationary (ceramic) part. F00636
Page 19
Maintenance
Shaft Maintenance/Replacement
Make sure bearings are clean; pack with grease as shown.
Water Slinger
Water Slinger
Oil Seal
Oil Seal
Remove volute to expose impeller. Peel off old volute gasket (or O-Ring) and discard. NOTE: Certain models such as the B4EY, are constructed with a suction cover which is removed first to access impeller.
GENERAL
Shaft assembly of S.A.E. mounted pumps should be periodically (annually minimum) torn down for inspection of worn parts, cleaning, and re-greasing. Most importantly, to check shaft sleeve and bearings for pitting. Replace worn components as necessary. Parts may be ordered separately as required, or for some models, shaft kits are available that are completely assembled and ready for installation.
PUMP DISASSEMBLY
Remove packing gland and packing arrangement as described in Page 17. Remove pump volute and impeller as described on Pages 18 and 19. Remove outer bearing cap and slide shaft assembly from bearing bracket. Clean and inspect all components.
SHAFT INSTALLATION
Page 20
Thoroughly steam clean or solvent wash the bearing cavity of bracket to remove old grease and dirt. Check surface of bracket for cracks, extreme corrosion, or other defects. Pack bearings with a lithium-based NLGI No. 2 extra pressure ball bearing grease (see Lubrication, Page 16). Force enough grease into each bearing to fill internal space between the races. Coat the bearing bores of bracket with oil. Orient shaft assembly in the direction shown above. Slide shaft and bearing assembly into bearing bracket. Do not force them! When threaded end of pump shaft comes through inside opening of bearing cavity, place oil seal, water slinger, and lantern ring over end of shaft. If packing gland or seal retainer is not of the split variety, place it over the shaft at this time as well. Slide shaft on through stuffing box until the first bearing makes contact with the bracket. Carefully align bearing with the bearing bore and press or tap bearing assembly into place. Do not use excessive force. NOTE: Be sure bearing bores and bracket area are clean and free of contamination or early bearing failure may occur. Reinstall outer bearing cap and oil seal. Rotate pump by hand, 10-12 rotations. Reassemble pump parts and reinstall unit to piping system. Refer to Installation section in this manual for correct procedure.
F00636
Maintenance
WINTERIZING
If pump is to be out of service for an extended period of time, such as the winter months, the following storage procedures should be followed. Remove exterior dirt and grime or any substance that may trap moisture. Exposed metal is subject to oxidation, prime and repaint if necessary. Coat machined surfaces with grease or heavy oil. Flush suction and discharge lines. Check for leaks at this time and replace any worn gaskets. Remove lowest plug in pump and drain pump casing and suction and discharge lines. Lubricate bearings. If possible, keep unit clean and dry during storage period to guard against corrosion. Seal all open ports to keep out foreign objects such as insects, rodents, dust and dirt. Rotate driver shaft periodically to prevent freeze-up of internal components. Shelter unit from elements if possible. Work oil into the wear ring by dripping oil into the gap while rotating impeller by hand. Winterize the engine according to the engine manufacturers instructions.
SPRING START-UP
Inject sufficient amount of grease into bearing to displace old grease. Perform a visual inspection of all components. Rotate by hand to be sure impeller and shaft turn freely. If binding occurs, disassemble and inspect. Follow engine manufacturers recommendations for starting the engine.
F00636
Page 21
Maintenance
Routine Inspection
Record I. QUARTERLY INSPECTION
Inspect all system piping connections for leakage or possible misalignment. Complete any lubrication requirements as dictated by pump and driver owners manual. Inspect packing or mechanical seal for possible replacement. Examine shaft sleeve, if present, for wear and replace if necessary. Check pump bearings from signs of wear. Repack or replace as necessary. Check alignment of flywheel coupling. ________________________________________ ________________________________________ ________________________________________
NOTES:
ANNUAL INSPECTION
Inspect pump and entire pumping system for signs of wear. Inspect system valves, screens, etc. Check pump impeller and balance ring for clearance. Inspect impeller, volute case, and seal chamber for signs of excessive wear or corrosion.
Page 22
F00636
Pump Nomenclature
General Information
ORDERING REPLACEMENT PARTS:
Locate the Berkeley nameplate on the pump, plate is normally on the bearing bracket. Information found on this plate is shown below. To be sure of receiving correct parts, provide all nameplate data when ordering. The BM (Bill of Material) number is most important. Write your nameplate information on the blank nameplate below for future reference as nameplates can become worn or lost. The illustrations on Pages 24 and 25 shows typical components used in the assembly of S.A.E. mount centrifugal pumps. Refer to these drawings when ordering any replacement parts.
788 0394 MODEL
SAMPLE ONLY
BERKELEY PUMPS
S.N. OR DATE
B3ZQM
IMPELLER DIA.
G123094
B.M.
9.00
B65999
BERKELEY PUMPS
MODEL S.N. OR DATE IMPELLER DIA. B.M.
344 1093
"B"=
In.
Size:
From Table I, Page 5 , SAE Housing Size is: Flywheel Dimensions (From page 7) "E"=
In. "F"=
Size:
Dim. "BC"=
In. "H"= In. In. "F2"=
In. In
In. "G"=
If all even except one, center to center of odd hole is For Fig. 4 symetrically grouped set of holes: "F1"=
In.
"Standard" Flywheel Coupling from Table IIA, IIB, IIC or Table III: (From page 7)
1463 0195
F00636
Page 23
Pump Nomenclature
Mechanical Seal
L
Outer Bearing Cap
Packing
Packing Gland
Shaft Sleeve
BE
RK
EL
EY
Pump Shaft
Centrifugal
Volute Case
Impeller Washer Impeller Capscrew Clack Weight mpeller Impeller Lock Nut Case Gasket Pump Case (Volute) Clack Washer Volute Gasket or O-Ring Suction Cover
5532 1006
Self-Priming Centrifugal
Rubber Clack (Check Valve)
Page 24
F00636
Pump Nomenclature
L L
Bracket Gasket Grease Seal Packing Nut Packing Gland Stud Packing Rings Slinger Seal Plate
Shaft Shaft Key Sealed Bearing Mechanical Seal Impeller Retaining Washer Ring Impeller Shakeproof Lock Washer Volute Gasket Impeller Capscrew Volute Case Shaft Sleeve
L water soluble
Lantern Ring Metallic Ring Packing Housing
Use only
Clack Washer
Case Gasket Pump Case (Volute) Rubber Clack (Check Valve) Suction Cover
F00636
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Troubleshooting
SYMPTOM GROUP I ELECTRICAL A B C D X X X X X X PROBABLE CAUSE GROUP II MECHANICAL B C D E F X X X X X X X X X X X CORRECTIVE ACTION Refer to engine manufacturers manual. Refer to engine manufacturers manual. Maximum engine speed not to exceed maximum performance curve speed as shown. Refer to engine manufacturers manual. Reprime. Inspect suction system for air leaks. Locate and remove obstruction. Check wearing surfaces. Inspect. Repair. Refer to installation instruction under Pipe and Foundation. Inspect for damage or insufficient diameter for condition. Compare pump pressure and flow rate against pump characteristic curve. Reduce system pressure requirement. Increase pressure capability of pump. Locate and remove obstruction. Check with gauge or measure vertical distance between water surface and center line of pump, allowing for friction loss in suction pipe. Reduce rate of flow to obtain desired lift. Refer to pump characteristic curve. Decrease rate of flow. GROUP III SYSTEM B C X X X X X X X X X
No water delivered Not enough water delivered Not enough pressure Engine heats excessively Abnormal noise and/or vibration CAUSE I. ENGINE A. Speed too low B. Rotating and/or reciprocating parts drag C. Speed too high D. Loose or broken parts II. PUMP A. Not primed B. Flow through pump completely or partially obstructed C. Internal leakage D. Rotating parts drag E. Case, bracket and/or shaft distorted F. Impeller III. SYSTEM A. Pressure required by system at design flow rate exceeds pressure rating of pump B. Obstruction in suction piping C. Suction lift too high
A X X
A X X X
X X
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F00636
Berkeley
Warranty
LIMITED WARRANTY
BERKELEY warrants to the original consumer purchaser (Purchaser or You) of the products listed below, that they will be free from defects in material and workmanship for the Warranty Period shown below. Product Water Systems: Water Systems Products jet pumps, small centrifugal pumps, submersible pumps and related accessories Pro-SourceTM Composite Tanks Pro-SourceTM Steel Pressure Tanks Pro-SourceTM Epoxy-Lined Tanks Sump/Sewage/Effluent Products Agricultural/Commercial: Centrifugals close-coupled motor drive, frame mount, SAE mount, engine drive, VMS, SSCX, SSHM Submersible Turbines, 6 diameter and larger Warranty Period
whichever occurs first: 12 months from date of original installation, or 18 months from date of manufacture
5 years from date of original installation 5 years from date of original installation 3 years from date of original installation 12 months from date of original installation, or 18 months from date of manufacture 12 months from date of original installation, or 24 months from date of manufacture 12 months from date of original installation, or 24 months from date of manufacture
Our limited warranty will not apply to any product that, in our sole judgement, has been subject to negligence, misapplication, improper installation, or improper maintenance. Without limiting the foregoing, operating a three phase motor with single phase power through a phase converter will void the warranty. Note also that three phase motors must be protected by three-leg, ambient compensated, extra-quick trip overload relays of the recommended size or the warranty is void. Your only remedy, and BERKELEYs only duty, is that BERKELEY repair or replace defective products (at BERKELEYs choice). You must pay all labor and shipping charges associated with this warranty and must request warranty service through the installing dealer as soon as a problem is discovered. No request for service will be accepted if received after the Warranty Period has expired. This warranty is not transferable. BERKELEY SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER. THE FOREGOING LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING WARRANTIES SHALL NOT EXTEND BEYOND THE DURATION EXPRESSLY PROVIDED HEREIN. Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on the duration of an implied warranty, so the above limitations or exclusions may not apply to You. This warranty gives You specific legal rights and You may also have other rights which vary from state to state. This warranty supersedes and replaces all previous warranty publications.
In the U.S.: BERKELEY, 293 Wright St., Delavan, WI 53115 In Canada: 269 Trillium Dr., Kitchener, Ontario N2G 4W5
F00636
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