Tsurumi Pump VANCS PU Series Overhaul Manual
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Tsurumi Pump VANCS PU Series Overhaul Manual

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OVERHAUL MANUAL
PU series
1

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  • Page 1 OVERHAUL MANUAL PU series...
  • Page 2 Release from Liability Upon reading this, the user of the respective Tsurumi product and Overhaul Manual acknowledges and understands Tsurumi Europe shall not be held liable for any user injury that occurs during the inspection and disassembly/assembly of the product. The users also acknowledge that they will be held responsible for any damage or destruction inflicted onto the product, and/or for the loss of parts during inspection and self-performed maintenance.
  • Page 3 OVERHAUL MANUAL 50PU2.4S | 50PU2.75S The following is a guideline for the overhaul of the single-phase Tsurumi PU Series submersible pumps. Use this guide, along with the parts list, exploded view diagram, and operation manual for your particular pump model to disassemble, inspect, and rebuild your pump to factory conditions.
  • Page 4 Exploded View (Reference: 50PU2.4S-53)

  • Page 5: Table Of Contents

    Sections • Electrical Testing Page • Inspect Oil Chamber Page • Inspect Pump Casing Page • Inspect Mechanical Seal Page • Motor Inspection Page • Pump Re-Assembly Page...
  • Page 6 Tools Required...

  • Page 7: Electrical Testing

    Electrical Testing Perform proper electrical testings. Please refer to the operation manual. All electrical work must be performed by an authorized electrician only in compliance with local electrical equipment standards and internal wiring codes. Never allow an unauthorized person to perform electrical work because it is not only against the law, but it can also be extremely dangerous.
  • Page 8 Cable Inspection Measure and inspect pump cable. Note total length of cable. Original cables, as supplied, are 10m length. If there are any cuts or other deformities in the cable, or the cable is less than 10m in length, the cable should be replaced. Inspect cable plug for damage and ensure that grounding prong is intact for safe operation.
  • Page 10 Cable Assembly Removal Remove the two bolts securing the cable gland to the head cover. CAUTION: If water has worked it’s way into the motor area, this can be under pressure and water can spray out. Wear eye protection. Carefully wiggle the cable assembly out of the motor casing and inspect the connections.

  • Page 11: Inspect Oil Chamber

    Inspect Oil Chamber It is recommended to inspect the oil every 6000 hours or 12 months of operation, whichever comes first. If there is water in the oil chamber or the oil level is low, this is evidence of a worn mechanical seal, which should be replaced before irreparable damage or bodily injury occurs.
  • Page 12 Oil Plug Drain and Inspect oil To drain the oil, remove the Oil Plug located on the oil casing, on the side of the pump. Oil casing may be under pressure, so be sure to wear eye protection, and shield the oil from Oil Casing spraying everywhere.

  • Page 13: Inspect Pump Casing

    Inspect Pump Casing for Wear and/or Debris If your pump motor is running but is not performing as new, there could be wear to the impeller or foreign debris stuck in the pump end.
  • Page 14 Remove Pump Casing Remove the hex boltss securing the pump casing. With the pump casing removed, inspect the pump casing, impeller, and discharge flange for wear and damage. Any worn components should be replaced to regain original performance of the pump. Remove any foreign debris from the wet end.
  • Page 15 Remove Impeller Remove the screw securing the impeller. It may be necessary to hold the impeller in place with pliers while unfastening the screw. Impeller Remove the impeller and set aside.

  • Page 16: Inspect Mechanical Seal

    Inspect/Remove Mechanical Seal If oil or debris was found in the oil chamber, or oil level is low, it is necessary to change the mechanical seal.
  • Page 17 Remove Oil Casing If there is evidence that mechanical seal is leaking (water or debris in the oil or motor has failed the Megger test), it will be necessary to remove the oil casing from the motor frame. Using a hex bit, remove the (4) bolts securing the oil casing. * Once these are separated, oil WILL leak out.
  • Page 18 Mechanical Seal Inspect Oil Casing, O-Ring, Oil Lifter, and Mechanical Seal. It is recommended to use only new packings and O-rings upon re-assembly, so the O-ring will NOT be re-used. Check for debris, or grit in the oil chamber, and make sure oil lifter is not cracked or otherwise damaged.
  • Page 20 Oil Lifter Remove Oil Lifter to expose the stationary seal The oil lifter is press-fit into the oil casing. Carefully lift this off to allow removal of the stationary portion of the mechanical seal.
  • Page 22 Remove Lower Stationary Seal Using a flat blade screwdriver, carefully pry the seal out of the casing. The seal should not be re-used, but in case of inspection, don’t crack or damage it.
  • Page 23 Remove Lower Rotary Seal (Impeller Side) With two flat blade screwdrivers, CAREFULLY pry the upper portion of the rotary mechanical seal up and remove this face along with the spring. Take care not to damage the rotor shaft with the screwdrivers.
  • Page 24 Remove Upper Rotary Seal (Motor Side) With the lower seal and spring removed, then remove the upper seal. Take care not to damage the rotor shaft with the screwdrivers.

  • Page 25: Motor Inspection

    Motor Inspection If your pump is tripping a circuit breaker or other device, this is evidence of an internal short in the motor or the cable. If your pump is making abnormal grinding noises or doesn’t spin, this is evidence of damaged bearings. Both would require disassembly and inspection of the motor components.
  • Page 26 50PU2.4S Remove Head Cover / Inspect Capacitor Remove the (4) bolts securing the motor head cover from the motor frame. Remove the motor head cover and packing. Capacitor should be visible at this point. If Capacitor capacitor visibly appears to be bulging, or is leaking electrolyte, it has over-heated and Motor Head...
  • Page 27 Test Capacitor Capacitance value written on capacitor Using wire cutters, cut the zip ties securing the wires going to the capacitor. Remove the lead wires from the capacitor. To avoid injury, discharge the capacitor by attaching the leads of your multi-meter to the leads of the capacitor while in Voltage AC setting.
  • Page 28 Remove Motor Bracket Remove (4) screws securing the Motor Bracket Place the motor on its side and tap the end of the shaft with a RUBBER OR PLASTIC hammer. (A metal hammer can cause damage to the shaft end not allowing the impeller to be replaced.) Place the motor upright and remove the motor bracket, taking care while pushing the wires through the bracket.
  • Page 29 Inspect Rotor, Stator and Bearings Stator With the motor bracket out of the way, pull up on the upper bearing and the rotor assembly should slide out. Motor Bracket If the stator does not visibly have evidence of being burned, but is wet from oil or water, it will need to be cleaned with compressed air/mineral spirits and baked in a low heat oven to properly dry.
  • Page 30 Replace Bearings Spin bearings. If bearings appear to wobble or spin Bearing rough, they should be replaced. A bearing puller puller will be necessary to properly remove bearings. When re-installing NEW bearings, it is recommended to heat the bearings so the inner diameter expands.
  • Page 32 Remove Upper Stationary Seals Carefully pry it out of the Bearing Housing. The seal will not be re-used, but in case of inspection, don’t crack or damage it.
  • Page 33 Inspect All Components for Replacement With disassembly complete, inspect all the components for wear or damage, and make a list of components that will need to be replaced. All Packings and O-rings should be replaced along with the mechanical seal and oil. For all other parts, use your discretion.

  • Page 34: Pump Reassembly

    Pump Reassembly Once all components have been verified to be in operable condition, we can now re-assemble the pump. New O-Rings and Packing materials are available as a kit, and should always be used upon re-assembly...
  • Page 35 Layout Mechanical Seal for Proper Placement It is very important that the mechanical seal components are oriented properly when installed. This is how they should appear on the shaft. Left to right = Top to bottom. Upper Upper Rotary Spring Lower Rotary Lower Stationary...
  • Page 36 Reassemble Stationary Seals • Coat mechanical seal components with fresh oil. • Carefully press upper stationary mechanical seal (ceramic) into Bearing Housing. • And press lower stationary seal (SiC) into the Oil casing. • Ensure seals are properly seated and sitting parallel to the casings. Press Oil Lifter into oil casing Oil Lifter Oil Casing Bearing Housing...
  • Page 37 Reassemble Motor Place the Motor Frame(w/stator) on top of bearing housing. Motor Frame Bearing Housing...
  • Page 38 Reassemble Motor • Place Rotor Assembly back into the stator assembly. • Place Wave Washer back onto top of upper bearing, and replace motor plate. • Set the Motor Bracket and Packing on to the Motor Frame per the alignment marks drawn during disassembly step. •...
  • Page 39 Secure Motor Assembly Re-install capacitor and attach leads from stator. For reference, the blue wire goes on the left (single lead), and black is on the right side – double lead. Replace head cover gasket and install the Motor Head Cover with the four securing bolts. Be sure the leas wires feed through the top of the head cover.
  • Page 40 Reassemble Rotary Seals • Coat rotor shaft with oil and carefully press Upper Rotary Seal (motor side) onto shaft until it touches the upper stationary seal. • Place Spring against rotary seal. • Press Lower Rotary Seal (impeller side) on the shaft. * Placing the pump upside down on a support (to protect the wires and capacitor)
  • Page 41 Reassemble Oil Casing Rotary seals will quickly compress on shaft, so run them back and forth on the shaft until oil casing is ready to be bolted to motor frame. Set new Packing to the oil casing. Tighten bolts, fastening oil casing to motor frame, and turn pump on its side. Spin motor shaft to ensure there is no binding and shaft spins smoothly.
  • Page 42 Reassemble Impeller Impeller vanes should face away from the motor. Secure impeller with truss screw & flat washer. Impeller...
  • Page 43 Air Tightness Test Oil Chamber With an air tight fitting, test if the mechanical seal is seated properly. If the chamber can hold for more than 1 minute, the seal is seated properly and will not leak.
  • Page 44 Fill With New Oil Provide the pump with correct amount of new oil by placing it on its side. Rremove the oil plug, and carefully pour in the correct amount of oil. Close the oil plug.
  • Page 45 Reassemble Wet End Set motor assembly on the pump casing. Ensure that tab of the oil casing is directly over the air release valve so as to contain the ball. Fasten the motor assembly to the pump casing with the 4 hex bolts. Pump Casing Motor Assembly...
  • Page 46 Reassemble Top End • Connect bullet connectors of cable assembly to leads from motor housing. Bullet connectors will ‘snap’ when they are fastened properly. • Fasten Cable Gland to the head cover using the two bolts. Make sure the cable gland is in its proper location. (The installation has to be performed by the qualified electrician only!)
  • Page 47 Perform Run Test Connect pump cable to single phase power with correct voltage. Make sure pump is pushing air and there is no abnormal noises coming from the unit. Pump should make a steady humming sound when running. If there are any questions, feel free to contact us at sales@tsurumi.eu.
  • Page 48 OVERHAUL MANUAL PU series...

This manual is also suitable for:

Vancs 50pu2.4sVancs 50pu2.75sVancs 50pu2.4s-53

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