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Fristam Pumps FKL-25 Instruction And Maintenance Manual

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FKL Series Pump

INSTRUCTION AND MAINTENANCE MANUAL:
FKL-25, 50, 75, 150, 250
400 S
P
AND
TyLE
UMP
SANITARy POSITIVE DISPLACEMENT PUMP

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Summary of Contents for Fristam Pumps FKL-25

  • Page 1 FKL Series Pump INSTRUCTION AND MAINTENANCE MANUAL: FKL-25, 50, 75, 150, 250 400 S TyLE SANITARy POSITIVE DISPLACEMENT PUMP...
  • Page 2 Fristam Pumps ESCRIPTION This manual contains installation, operation and repair instructions for the Fristam FKL 15, 0, 5, 50, 75, 150, 50 and 400 Series balanced circular piston pump. The FKL pump is a positive displacement pump characterized by its balanced rotor design. The rotors travel through a precisely machined, close clearance channel in the housing and cover allowing the product to be pumped very efficiently.

  • Page 3: Table Of Contents

    FKL Series Pump AbLE OF ONTENTS ..................4-6 efeRence ateRial ..................4 echnical nfoRMation ......5 oupling lignMent and ecoMMended oRque alues ables fKl R ..................6 otoR leaRances ....................... 7-9 nstallation ..............10 ecoMMended ReVentiVe aintenance ................10 leaning ecoMMendations ..................11-17 eplaceMent ................11-12 isasseMbly ..............13 echanical...

  • Page 4: Reference Material

    Fristam Pumps EFERENCE ATERIAL EChNICAL NFORMATION PECIFICATIONS Normal Differential Pressure Range ................. 0 to 300 PSI Normal Speed Range ....................0 to 600 RPM Normal Temperature Differential (Standard Rotors) ............140°F ∆ Normal Temperature Differential (High Temperature Rotors) ........∆10°F...
  • Page 5 FKL Series Pump Woods Sure-Flex Coupling Alignment Type E Type H Sleeve Angular Angular Parallel Parallel Size Y max. - Y Y max. - Y min. min. .015 .056 1.938 .015 .070 2.375 .010 .016 2.375 .020 .081 2.563 .012 .020 2.563 .020...

  • Page 6: Fkl R Otor C Learances

    Fristam Pumps A3: FKL R AbLE OTOR LEARANCES Standard Rotors High Temperature Rotors Model Back Face Radial Front Face Back Face Radial Front Face 0.06-0.08 0.05-0.09 0.07-0.17 0.11-0.12 0.08-0.12 0.13-0.23 (0.0024-0.0031”) (0.002-0.0035”) (0.0028-0.007”) (0.0039-0.0047”) (0.0031-0.0047”) (0.0051-0.0091”) 0.07-0.11 0.055-0.105 0.08-0.20 0.11-0.15 0.095-0.145...

  • Page 7: Installation

    FKL Series Pump NSTALLATION NPACKINg Check the contents and all wrapping when unpacking the pump. Carefully inspect for any damage that may have occurred during shipping. Immediately report any damage to the carrier. Leave the protec- tive caps over the pump inlet and outlet connections until you are ready to install the pump. NSTALLINg Prior to actually installing the pump, ensure that: •...
  • Page 8 Fristam Pumps • Keep suction lines as short and direct as possible. • Avoid abrupt transitions in the piping systems (Figure 4). • Avoid the formation of air pockets in the piping (Figure 5). Figure 4 • Ensure that the NPSH available in the system is greater than NPSH required by the pump.

  • Page 9: Recommended Preventive Maintenance

    A change in conditions (for example, higher viscosity product, higher product specific gravity) can overload the motor. For technical assistance regarding operating condition chang- es, please contact Fristam Pumps. Make sure that the pump is rotating in the correct direction.

  • Page 10: Eal Eplacement

    Fristam Pumps See the oil capacity listing on page 5. ERIODIC AINTENANCE Periodically inspect the pump housing, cover and rotors for any signs of wear or damage. If wear is present this could be a sign of over-pressurization, incorrect rotor gap or bearing wear.

  • Page 11: P Ump E Nd D Isassembly

    FKL Series Pump Seal assembly tool or a press (part number 1018000011) OOLS EqUIRED FOR PECIFIC ODEL WRENCh SIzE IN MM FKL 5 FKL 50 FKL 75 FKL 150 FKL 50 FKL 400 cover nuts 13 mm 19 mm 19 mm 19 mm 19 mm 19 mm...

  • Page 12: Disassembly Of Seal Cartridge For Mechanical Seals

    Fristam Pumps c) Remove the seal housing screws, seal cartridges and seal housing o-rings as shown in Figure 13. d) Remove the two rotating seal rings and rotating seal o-rings from the pump shaft. If replacing the cartridge with a new cartridge proceed to the ‘Seal...
  • Page 13 FKL Series Pump bly tool or press. Figure 13 b) Insert the seal compressor disc onto the seal face. c) Use the seal assembly tool to compress the seal ← so that all of the pressure is off the seal retaining Double and Aseptic seals only ring.

  • Page 14: Seal Cartridge Installation

    Fristam Pumps pins. g) Set the seal retaining ring on top of the seal hous- Figure 15 ing. h) Push down on the outer stationary seal until it is past the seal retaining ring groove. ← Double and Aseptic seals only i) Use your fingers to fit the seal retaining ring into ←...

  • Page 15: Seal Assembly For O-Ring Seals

    FKL Series Pump SSEMbLy EALS Figure 17 a) Place the pump housing face down as shown in Fig- ure 17. b) Install the new inner stationary seal o-rings into the grooves in the seal housing. ← Double seal only c) Install the new seal o-rings into the o-ring seal hous- ings.
  • Page 16 Fristam Pumps e) Align the rotors with the pump shaft so that the large spline teeth on the rotor slide into the missing teeth on the pump shaft. f) Place the new rotor cap o-rings into the groove on the rotor caps.

  • Page 17: Earing And Or Haft Eplacement (Fkl 25, 75, 150, 250 & 400)

    FKL Series Pump d) Replace all shaft guards. e) Reconnect the inlet and outlet piping. f) Install the seal flush piping as shown in Figure 0. g) Replace the seal flush supply and return lines to your pump if the pump is equipped with a double mechanical or double o-ring product seal.

  • Page 18: Earbox Isassembly

    Fristam Pumps NDICATINg TORqUE WRENCh OOLS EqUIRED FOR PECIFIC ODEL FKL 5 FKL 75, 150 & 50 FKL 400 Gearbox cover bolts 13 mm wrench 17 mm wrench 17 mm wrench Bearing cap screws 5 mm Allen wrench 6 mm Allen wrench...

  • Page 19: Etting The Otor Ap

    FKL Series Pump position. SSEMbLE FRONT bEARINgS ONTO ShAFTS Cover the coupling area of the drive shaft with tape, to protect it. Lightly grease the front bear- GEARBOX ing step on the pump shafts. a) Press the front bearing cone on the shaft. Use a hose clamp or tape to hold the cups ARBOR PRESS and outer spacer together (Figure 4).

  • Page 20: Install The G Earbox

    Fristam Pumps propriate wrench to the torque specified in Table A, page 5. k) Now place the Figure 5 wooden dowel between the ro- tors as shown in Figure 7. l) Tighten the second rotor bolt clockwise with the appropriate...
  • Page 21 FKL Series Pump the shaft. c) Place one of the gears with Figure 7 the part number facing the bearing lock nut end of the gearbox, into the gearbox. d) Install the shaft through the front bearing bore of the gearbox and through the gear.
  • Page 22 Fristam Pumps appropriate Allen Figure 9 wrench. g) Place the new gear- box cover gasket and gearbox cover on the gearbox and secure with the gearbox cover bolts. Tighten to the torque speci- fied in Table A, page h) Re-install the oil...
  • Page 23 FKL Series Pump Figure 31 IL-0528 DIAL INDICATOR Figure 3 PUSH AND PULL ON THIS END OF SHAFT. CHECK DIAL INDICATOR FOR MOVEMENT. PLACE DIAL INDICATOR ON THESE SURFACES TO CHECK FOR ZERO ENDPLAY ON BOTH SHAFTS. 1265000025 5/14/02...

  • Page 24: Earing And Or Haft Eplacement (Fkl50)

    Fristam Pumps FKL 50 S EARINg AND hAFT EPLACEMENT FOR ERIES CAUTION! Begin all pump maintenance by disconnecting the energy source to the pump. Observe all lock out/tag out procedures as outlined by ANSI Z44.1-198 and OSHA 1910.147 to prevent accidental start-up and injury.

  • Page 25: Earbox Ssembly

    FKL Series Pump bor press with the spline ends of the shafts facing down as shown in Figure 34. Press on both shafts to remove them from the gearbox until you hear a click. This will GEARBOX be the sound of the snap ring falling into the groove of the shaft behind the bearing lock nut thread.

  • Page 26: Install The G Earbox

    Fristam Pumps NSERT ThE OUTER bEARINg RACES Lightly grease the front and rear bearing bores. Insert the outer races of the front and rear bear- ings into the gearbox as shown in Figure 35. Ideally these races should be pressed in using an Arbor press and an old bearing race ground down to slide freely in the bearing bore.
  • Page 27 FKL Series Pump slide on the shaft (Figure 38). Hold the bearing in place for a few seconds so the bearing has a chance to cool. g) Install the bearing spacer, the bearing lock nut washer and the bearing lock nut onto the shaft (Figure 38).

  • Page 28: Etting The Otor Ap

    Fristam Pumps The rolling torque should be 7 in-lbs. if it is not, tighten or loosen the bearing locknut as needed. m) Turn the rotors to check the timing. If the timing is off, one shaft will have to be removed and then reinstalled.
  • Page 29 FKL Series Pump With the bearings properly assembled, you are now ready to set the rotor gap. This is accom- plished by placing shims between the front bear- ings and gearbox as shown in Figure 4. To check the rotor gap, the pump housing and ro- tors need to be installed.
  • Page 30 Fristam Pumps 1265000005 Rev - FKL (25, 75, 150, 250 & 400) E xPLODED...
  • Page 31 FKL Series Pump...
  • Page 32 Fristam Pumps FKL 25 P UMbERS Item Item Description Qty. Part No. Description Qty. Part No. Bearing cap screw 1101000048 Pump cover 1656620000 Rear bearing cap (drive shaft) 1304000010 Forcing screw 1018000012 Rear bearing cap (idle shaft) 1304000011 Gearbox cover gasket...
  • Page 33 FKL Series Pump FKL 75 P umbers Item Item Description Qty. Part No. Description Qty. Part No. Bearing cap screw 1101000032 Pump cover 1660620000 Rear bearing cap (drive shaft) 1304000013 Pump cover (rectangular inlet) 1660620001 Rear bearing cap (idle shaft) 1304000014 Forcing screw 1018000012...
  • Page 34 Fristam Pumps FKL 150 P umbers Item Item Description Qty. Part No. Description Qty. Part No. Bearing cap screw 1101000032 Pump cover 1668620000 Rear bearing cap (drive shaft) 1304000002 Pump cover (rectangular inlet) 1668620001 Rear bearing cap (idle shaft) 1304000003...
  • Page 35 FKL Series Pump FKL 250 P umbers Item Item Description Qty. Part No. Description Qty. Part No. Bearing cap screw 1101000032 Pump cover 1670620000 Rear bearing cap (drive shaft) 1304000005 Forcing screw 1018000013 Rear bearing cap (idle shaft) 1304000006 Gearbox cover gasket 1181000053 Bearing cap o-ring (buna) 1180000214...
  • Page 36 Fristam Pumps FKL 400 P UMbERS Item Item Description Qty. Part No. Description Qty. Part No. Bearing cap screw 1101000036 Pump cover 1672620000 Rear bearing cap (drive shaft) 1304000009 Forcing screw 1018000013 Rear bearing cap (idle shaft) 1304000008 Gearbox cover gasket...
  • Page 37 FKL Series Pump...
  • Page 38 Fristam Pumps FKL 50 E xPLODED 39. Gearbox cover bolt 1. Guard nut 1. Bearing cap screw 40A. Gear snap ring . Housing guard . Bearing cap (drive shaft) 41. Gear 3. Small mounting pin 3. Bearing cap (idle shaft) 43.
  • Page 39 FKL Series Pump...
  • Page 40 Fristam Pumps FKL 50 P umbers Item Item Description Qty. Part No. Description Qty. Part No. Bearing cap screw 1101000016 Pump cover 1658620000 Rear bearing cap (drive shaft) 1304000000 Pump cover (rectangular inlet) 1658620001 Rear bearing cap (idle shaft) 1304000015...
  • Page 41 FKL Series Pump FKL s iNgLe echaNicaL Item Description Rotor/rotor cap o-ring (viton) 1180000243 1180000120 1180000014 1180000115 1180000212 1180000234 Rotor/rotor cap o-ring (EPDM) 1180000244 1180000183 1180000063 1180000205 1180000213 1180000235 Plastic cap plug 1248000006 Rotor bolt o-ring (viton) 1180000085 1180000095 1180000398 Rotor bolt o-ring (EPDM) 1180000188 1180000129...
  • Page 42 Fristam Pumps FKL D oubLe echaNicaL 1265000039 Rev. A Item Description Rotor/rotor cap o-ring (viton) 1180000243 1180000120 1180000014 1180000115 1180000212 1180000234 Rotor/rotor cap o-ring (viton) 1180000244 1180000183 1180000063 1180000205 1180000213 1180000235 Rotor bolt o-ring (viton) 1180000085 1180000095 1180000398 Rotor bolt o-ring (EPDM)
  • Page 43 FKL Series Pump FKL s iNgLe riNg 1265000150 Rev. A Item Description Rotor/rotor cap o-ring (viton) 1180000243 1180000120 1180000014 1180000115 1180000212 Rotor/rotor cap o-ring (viton) 1180000244 1180000183 1180000063 1180000205 1180000213 Rotor bolt o-ring (viton) 1180000085 1180000095 1180000398 Rotor bolt o-ring (EPDM) 1180000188 1180000129 1180000399...
  • Page 44 Fristam Pumps FKL D oubLe riNg Item Description Rotor/rotor cap o-ring (viton) 1180000243 1180000120 1180000014 1180000115 1180000212 Rotor/rotor cap o-ring (viton) 1180000244 1180000183 1180000063 1180000205 1180000213 Rotor bolt o-ring (viton) 1180000085 1180000095 1180000398 Rotor bolt o-ring (EPDM) 1180000188 1180000129 1180000399...
  • Page 45 FKL Series Pump FKL A SEPTIC PTION STEAM Aseptic designs are available for most of the FKL models. All of the dynamic and static seals are steam traced to ensure product sterility. STEAM Available: FKL 5 -400 Seal Max. Pressure: 40 psi Housing Rotating Connections: 1/16”...

  • Page 46: Roubleshooting

    Fristam Pumps ROUbLEShOOTINg Fristam pumps are relatively maintenance free; however, in the event that a problem arises, the following troubleshooting chart will help you with most of your pump-related problems. If a motor or drive problem arises, please contact your local motor repair representative.
  • Page 47 FKL Series Pump AINTENANCE ECORD Date Service Performed...
  • Page 48 Fristam Pumps AINTENANCE ECORD Date Service Performed...

  • Page 49: Otice Of Terms Warranty Provisions Including Disclaimers Claims And Limitation Of Liability

    All orders are subject to acceptance by Fristam Pumps USA Limited Partner- ship. Each Fristam Pumps item is warranted to be free from manufacturing defects for a period of one (1) year from the date of shipment, providing it has been used as recommended and in accordance with recognized piping practice, and providing it has not been worn out due to severe service, such as en- countered under extremely corrosive or abrasive conditions.
  • Page 50 Fristam Pumps Fristam Pumps USA Limited Partnership 410 Parview Road • Middleton, WI 5356-54 1-800-841-5001 • 608-831-5001 Part #: 1050000038 Drawing # 150000001 Rev C Updated 2/15/08 Website: www.fristam.com Email: fristam@fristampumps.com...

This manual is also suitable for:

Fkl-50Fkl-75Fkl-150Fkl-250Fkl-400

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