TOSHIBA

E KC00308 5-a

INSTRUC.,r-ION MANUAL
SEAL OIL PUMP
(MAIN SEAL OIL PUMP)
(EMERGENCY SEAL OIL PUMP)

NOTE
READ THESE INSTRl CTIONS CAREFULLY
SAVE THESE INSTRUCTIONS

TDS HIBA CORPORATION .

The information in this material is cc nfidential and contains Toshiba's intellectual

incl Jdina
know-how. It shall not be disclosed to anv third party, copied, reproduced, used for unauthorized purpose nor
modified without prior written consent of Toshiba.
Toshiba Corpore tion

P 1 / 34

INSTRUCTION MANUAL
THREE PINDLE SCREW PUMP

MAIN SEAL IL PUMP (GH-R1T-214)

EMERGENCY SE
OIL PUMP (GH-R1T168)

Ltd.
P3M-35562
P3M-35563

P 2 / 34

Table of content
Pa e
Safety instruction

The Foreward

1. Introduction
1. 1 Outline
1. 2 Denotation of pump t
2.

3
3
4

Structure

3. Installation and piping

3. 1 Installing place
3. 2 Foundation
3. 3 Installation
3. 4 Installing suction pipi g ..
3. 5 Installing discharge pi ing :
3. 6 Alignment
... .-.............. , ..................................... .
4.

Operation
4. 1 Preparation for operati n
4. 2 Operation start
4. 3 During operation
4. 4 Stopping

5. Maintenance and inspecti n

5. 1 Maintenance
5. 2 Periodical maintenance
5. 3 Allowance

6
6
6
6
7

7
8
9
10
10
10
11

12
12

13
14

Causes of trouble and cou ter measures .. .. .. .... ..

15

7. Disassembling and reasse bling .. .. .. .. .. .. ..

7. 1 Disassembling
7. 2 Reassembling

16
16
17

8. Drawing

18

6.

P 3 / 34

afety Instructions

autions for your safety

Before using this pump, read th

instruction manua I. Fo II ow warning I abe I, instruction

and caution plate in order to us

it correctly. It is also highly recommendedto alw ys

keep the instruction manual at the same place for easy access.
Transportation, i nsta II at ion, piping, wiring, operation, inspection and rna i ntena ce
work must be done by on I y a I ice sed and

or authorized person who has enough know I e ge

on health and safety- rules and regulations as well as on his or her profession.
In any respect, we wi I I not gu rantee any death, injuries, damages and losses which
are resu It in modification wit out our written authorization or using and assemb I i ng
unauthorized parts.
When disposing a pump, any ac essories, used parts and oi I, they should be trea ed
as a general industrial waste.
Warning label and sign in the i struction manual are classified into war~ing, caut on
and notice as descr i bed be low.

lndicat s a potentially hazardous situation which, if not avoided,

could suit in death or serious injury.

<!>WARNING

lndicat s a potentially hazardous situation which, if not avoided,

may re ult in minor or moderate injury.

Lh. CAUTION

/\.

NOTICE

in.dicat s a potentially hazardous situation which, if not avoided,

may re ult in damaging or defecting a product It will be only use
l for pro ecting the property, but not for personal safety.

~--------------~

1
P 4 / 34

The foreword
1.

This instruction manual is o understand the correct handling method of

equipment. Read and unde stand the contents of the instruction manual be ore
operation and maintenance ork.

2.

The instruction manual is i tended to cover all the situations of operation and
maintenance. When any que tion or inquiry arises concerning the content of the
instruction manual, contact osaka Laboratory Ltd.

3.

The content ofthe instructi n manual is the property ofKosaka Laboratory Ltd.
and is strictly confidential to nauthorized personnel or any third party.

4.

The 'mailing address, the items to identify the products and the necess ry
information for trouble shoot ng are as follows.
1) The mailing address
KOSAKA LABORATORY
TOKYO HEAD OFFICE
Mikuni East Bldg., 6-13
Tokyo 101-0021 JAP
TEL: 03-5812-2011 (J

TD.
ALES DEPT.
10, Sotokanda, Chiyoda-ku,
AN),

FAX: 03-5812-2015 (JAPAN)

2) Inquiry contents
Serial number, Pump na e, Type, Capacity, and Discharge pressure.
Explanation on abnorm l occurrence together with the preceding and curr nt
situation.
5.

Delivery Inspection
Inspect the following immed ately after the delivery of the pump.
1) No damage during transp rtation.
2) Specification matches the required specification.
3) No missing of accessories nd spare parts.
If any question arises, plea e contact to the supplier.

P 5 / 34

1. Introduction
Do not moe ify the equipment without the written consent of
KosakaLa poratory Ltd.

<!>WARNING Understan ~ the content of the instruction manual

thoroughly before any work. When maintenance covers
equipment with an electric motor, cut the electricity supply
switch off.

Outline
Kosaka three spindle scr ~w pump is designed and manufactured on the base of
the advanced technology b acked up by the long historical experience. The pum1 is
a displacement type cons sting mainly of a power rotor, two idler rotors an( a
sleeve. The pump has the f ollowing features and is applicable for many fields.

1.1

The features are as follows:

(1) Reliable operation
The simple structure e nsures the reliable and consistent operation.
(2) High efficiency
The pump performs w 'th high efficiency because of low friction loss and 1pw
leakage.
(3) High suction
Cavitation hardly occu rs because of the high suction capacity of the pump.
(4) Long life
The optimal selection of pump materials and power-transfer through liq id
without contact betweer the power rotor and idler rotors assure the long life.
(5) No pulsating flow
The pump operates wi h little vibration and low noise, because the dischar ed
liquid forms perfectly co ntinuous flow without pulsating.
(6) Compact size
The high-speed operati on makes the pump size compact.

<

''

3
P 6 / 34

1. 2 Denotation of pump type

The denotation of pump

2_~_4_ __

GH- R2TL___
1

t~pe

is as follows.

Screw number
Denotation of surface treatment and balance mech nism
S : standard type
T : nitriding treatment applied
B :. nitriding treatment and balancing mechanism
D : balance disk type (nitriding treatment and bal. ncing
mechanism)

Number of chambers kept closed by power and id er

rotors.

Pump in which ball bearings are used (no symbol R

given to the balance disk type though it is fitted
cylindrical roller bearings.

Denotation of type of pump

H : horizontal type
V : vertical type
C : flanged tvoe

Symbol ofKosaka three spindle screw pump

4
P 7 / 34

2.

Structure
The structure of the t ree spindle screw pump is shown on the draw ng
"Sectional Assembly" in Ar icle 9. A shaft coupling transmits power from a nio or
to the power rotor. The p wer rotor is supported with a front and a rear bearng,
while the idler rotors are upported with a sleeve. The handling liquid lubrica es
the plain bearings, therefo e external lubrication is unnecessary.
The mechanism of balanci g thrust load acting on the rotors is as follows.
Power rotor ; Thrust 1 ad is balanced by high-pressure liquid spouted fro a
port mad in the power rotor to act on the end of the shaft.
Idler rotors ; Thrust 1 ad is balanced by high-pressure liquid acting on t e
end of th balance piston.
When the handling liqui does not have sufficient lubricating property, the id er
rotors contact with the sle ve to cause wear. In this case, surface treatment is
applied to the power roto , the idler rotors and the sleeve to prevent wear. A
certain type of pumps has a balance mechanism to apply the hydraulic press re
between the idler rotors an the sleeve.
The structure of the main arts are as follows.

Casing
The casing is made in a b ock form with its inside divided into two chambers t
the discharge side and the uction side. The contacting positions of both the fro t
and rear covers to the sl eve are machined concentrically, and the bearin s
provided in each cover support the power rotor along the central axis of the sleev
(2) Power rotor
The power rotor is a shaft ith screw machined on the shaft. The shaft transm s
driving force and the sere acts as a pump. The screw is a double-thread ty e
and the lead of the screw is orie to two times of the outside diameter of the sere
The power rotor with a long screw (multiple chambers) is applicable
high-pressure operation.
(3) Idler rotor
The idler rotors are als machined to have double-thread screws, outsi e
diameters are 3/5 of the po
(4) Sleeve
The power rotor and idle rotors are inside of the sleeve, which is fixed to t
casing. Since the power rot r and idler rotors rotate in the sleeve, the surface
the sleeve is machined and mished.
(5) Bearings
The ball bearing and plain bearings are used.
(6) Mechanical seal
The mechanical seal preve ts leakage of a liquid.
(7) Ball valve
,
The ball valve prevents incoming of air into the pump.
(8) Relief valve
The relief valve prevents t e abnormal increase of discharge pressure.
(1)

5
P 8 / 34

3 . Installation and piping

<f>wARNIN

Transpor
with suffi
required
and cente

the equipment by licensed or authorized personnel

ient knowledge. Special attention and caution are
hen fitting a hanging wire in relation to its weight
of gravity.

Do not pu a hand and a foot under heavy equipment.

To neglec this instruction may result in pinch or injury.
3. 1 Installing place
(1) Install a pump in a place to achieve easy operation, mainten
disassembling a:pd rea sembling. Do not put hands or feet under heavy w
equipment.
3. 2

Foundation

(1) Make concrete founda ion in an area with space 'and depth sufficient to b ar

the weight of a pump a d to prevent frost heaving, because concrete placed on

soft ground may sink or tilt.
(2) Make a hole in the concrete foundation with sufficient clearance or
embedding foundation olts according to the drawing or the size of actual bo ts
level the surface ofthe oncrete.
(3) Install the pump after the concrete solidifies thoroughly.
3. 3 Installation
(1) Place a common bed to ether with a pump and a motor on the foundation.
Insert metallic wedges between the bed and the foundation leaving suita le
gap tobe filled with cern nt mortar later.
(2) Support the bed tho oughly as shown in Fig. 2. If the bed is partia ly
supported as shown in igure 1, the pump may result in distortion.

GOOD

Figure 1

Figure 2

6
P 9 / 34

(3) Insert anchor bolts t rough the bed at the designed points, screw nuts to the.
bolts to the top of the n ts and hang down the anchor bolts into holes.

Figure 3
(4) Check horizontal level fthe bed to meet the tolerance.
(5) Charge cement mortar to fill up space under the common bed and the anc or
bolt holes. Wait for so 'dification of the concrete, 'and fasten the nuts of he
anchor volts evenly.
3. 4 Installing suction pipin
(1) Minimize length ofsu tion piping and the number of bending. Install pro er
supporting devices to ee the pump from the weight of the piping.
(2) Do not make bends wi h small curvature radius, sharp change in diamete of
piping or sharp chan e of flow direction. Install a gasket at flange joi ts
properly not to interru t the flow inside the piping.
(3) Do not allow any part of the piping rise in a form allowable to contain air in
the piping.

,
(4) Install joints not to a ow leakage of air into the piping. Air in the pip ng
may result in the pump failure.
(5) Install a strainer with more than 40-mesh or equivalent in the piping.
(6) Position an intake o the pipe from the bottom of an oil tank to prev nt
sucking of sand or forei n objects.
(7) Clean and remove for ign objects such as welding chips or scale remaining in
the piping.
(8) Install a gate valve at he suction pipe for easy disassembling and inspectio .
Keep the valve open fu y while the pump is operating. The valve is only or
disassembling and insp ction.
3. 5 Installing discharge pip ng
(1) Install an air ventilat' on valve at the highest position in the piping.
(2) Install a gate valve o the pipe at the pump for easy disassembling a d
inspection. Install pro er supporting devices to free the pump from the wei ht
of the piping.

7
P 10 / 34

3. 6 Alignment
Check shaft centering f a pump and a motor as follows. Clean the o
peripheral surface of coup ings with thinner or some suitable solvent. Measure
deviation at four points o the periphery of the each coupling hubs as show
Fig. 4. Adjust the shaft enter position and the surface gap of the pump and
motor within the differenc in the measured values 0.1 mm under, by insertin
adjusting liner.
See separately attached i struction manual for the information concerning
handling, installation and maintenance of coupling.
(1) With the dial gauge ounted on the driven shaft coupling hub, rotate .b th
hubs together to check he centering, adjust if necessary (See figurEJ4- 0.

Figure 4- 1

(2) With the dial gauge m unted on a coupling hub, rotate both hubs together t
check the gap between he flanges, adjust if necessary (See figure 4- 2).

Figure 4- 2

8
P 11 / 34

4. Operation
Never a low unauthorized personnel to operate the pump.
Do not tpuch or contact any rotating part.
Confirm the safety of personnel around the pump before
operatiojn start.

Installll relief valve at the pump to secure safety. The

/f""VWARNING
pressurE ofthe pump without the reliefvalve may increase
excessiv~ly.

Do not operate the pump without a coupling cover.

To neglect this instruction may result in rolled in or injury.
Keep
1n.

clo~;hes

off the pump during operation to prevent rolled

Do not t uch or contact sealing part and hot parts while the
pump is in operation.

&

Check tl e leakage of piping during pump operation, and stop

the pump immediately after detecting the leakage.

CAUTION Reinstal a protection cover for rotating parts removed for

inspecti< nor maintenance.
Do not t uch or contact the pump when the pump is under
operatio p with high temperature. To neglect the instruction
may res lt in burn.
Remove
pump.

~oupling bolts

and check the rotating direction of the

Jog the 1 ump to confirm the rotating direction when the

coupling bolts are not removed.

D.

Do not ~ tart the normal operation of the pump immediateHr

after inf tallation. Rotate the pump with hands to confirrp.
smooth
otation, and operate the pump for a short time tp
NOTICE
check se lleakage, abnormal vibration, noise, etc.
Stop the pump immediately after detecting abnormal thing.
Check tl e cause of trouble, repair the trouble, and restart the
operatio after confirming the safety.
Operate !valves and cocks according to the operation manual.
Do not pperate valves and cocks improperly during pum
operatio .

P 12 / 34

4. 1 Preparation for operation

(1) Confirm valves of both suction side and discharge side open before operati< n
start.
(2) Do not touch or conta~t any rotating parts, and keep clothes off rotating
parts.
Table 2 Prenaration for oneration
Checkpoint

Item
Installation

The pum1 is installed properly.

Alignment

The moto and the pump are aligned satisfactorily.

Rotation

The pumf rotates smoothly with hands.

The hand ing liquid meets the specification.

Liquid

Fill the pipe with the liquid when piping has long distance
between the tank and the inlet port of the pump.

Liquid
temperature

The liquic temperature is within the range shown in the

specificaf on.

Difference in
temperature

The temp rature difference between the liquid and the pump
casing is l~ss than 20C. If it is over, do not start the pump.

Valves

The valve~ at both the discharge and the suction side are
opened fu ly.

Liquid in pump

Fill the pl mp with the liquid.

Air bleeding

Evacuate

Direction

The pump rotates in the normal direction.

~ir

in the piping.

4. 2 Operation start
(1) Stop a pump, if the pump does not suck liquid within 10 seconds af er
operation start.
(2) Do not do dry running operation, which causes seizing of the rotary parts.
(3) Check and confirm tl: e discharge and suction pressure within the desigr ed
pressure.
(4) Run the difference betv een suction pressure and discharge pressure kept at
more than 0.2 MPa.
(5) Measure the temperature of a casing and a bearing to check the lo ~al
temperature rise.
rrhe temperature must be less than the ambi{ nt
temperature plus 40C and less than the liquid temperature plus 20C.
(6) Confirm an electric current ofthe motor at a normal level.
4. 3 During operation
(1) Follow all instructions given in 4 2 above during operation.
(2) In case the liquid witl significantly different temperature from the curren~ly
handling liquid is supplied to the pump; keep changing ratio of the liq id
temperature less than l0C for 20 minutes. The higher changing ratio may
result in seizing of sere !vs.

10
P 13 / 34

(3) Check abnormal vibration of the pump. The allowable vibration depends on
the speed as follows:

Speed (n inl)
ALLSP~ED

Vibration ( f.1 m)
20

(Double Amplitude)
(4) Check abnormal chan~ing noise of the pump.
(5) Check leakage from the mechanical seal. The allowable amount ofleaking
liquid from the inechat ical seal is 3 m i !h.
4. 4 Stopping
When a pump is stopped s a stand by pump for a high temperature liquid, k ~ep
the pump run reverse for fvarming up. The standard number of pump speed for
warming up ranges from 3 0 to 60 min 1

11
P 14 / 34

5 . Maintenance and inspection

/f'
""V

Do not ~se any fire around the pump, when the himdling
liquid i inflammal;lle. To neglect the instruction may result n
explosi< nor fire.
WARNING 1 - - - + - - - - - - - - - - - - - - + - - - - 1
Sign clearly "In maintenance work" and cut off the electricit)l
source, before maintenance start.
.
Do not ~tart the pump unexpectedly during disassembling or
reasserr bling. Sign "Do not put the switch on".

&

CAUTION Check t~e leakage of the pump regularly at least once a day.
Repair he pump immediately, if an unusual seal leakage
occurs.

5. 1 Maintenance
Since the pump has three rotors engaging with one another with a relath ely
small gap in the sleeve, fo eign objects in liquid may bite or flaw the thread or "he
bearings.
Dry running with some defects may cause seizing in the worst case. Such a f aw
grows to increase the temJ erature at a local spot or to increase an electric current
of a motor. In such a casE, disassemble the pump to check the flaw.

12
P 15 / 34

5.2 Periodical maintenance

Maintenance
Item

Power
and
idler
rotor

Screw and
surface to
contact
bearing

Sleeve

Inner
surface

Plain
bearing

Bearing
surface

Roling bearing

Counter measure

Ins{ ection
Inspects rface of
screws ar d rotors for a
mark or a dent by
contact. Measure the
outside d. ameter of
rotors.
Inspect ir ner surface
fora mar , a dent by
contact or a flaw.
Measure nside
diameter of sleeve.
Inspect hE aring surface
for a mar , a dent by
contact or a flaw;
Inspect tl: e rolling
bearing fc rthe
presence ~f exfoliation
and defor rnation.
Change gj ease.
Inspect s al surface.

Mechanical seal
Packing and
gaskets
Shaft coupling

If a rotor itself or a screw

wears abnormally,
replace the rotor set.

Frequen y
One ye r
or 8000h

0
If a bearing surface .
wears abnormally,
replace the bearing.
If anything unusual is
found, replace it with
new one.

Replace the mechanical

seal, if anything
abnormal is found.
Replace the packing or
gasket during overhaul.

Inspect a l parts for a If anything unusual is

found, replace the
flaw and ear.
coupling.

0
0
0

'

13
P 16 / 34

5. 3 Allowance
When the dimension of t e rotors, the sleeve, and the bearings is out of the
following allowance, replace he parts with new ones.

EA
,r. ~ -

-f===:-:>~lr---i _II+H--t--:""-1-1,
L...---'--b_='-.11
t-

"""'r~

-A\

----~70-

r't-rll f=

--: ~ ~
-------/1- ~- --~~

--

..,~

lf

-~-r---'/{;11--S
- \LI -

vY-Q

G
UNIT:m n

Figure 5.

POSITION
DESIGNDED
w TOLERANCE

....J

:c ALLOWABL
E (Max.)
1LL

TOLERANCE

<

:c ALLOWABL
C/)
E

(Min.)

62

25

63.5

+ 0.030

+ 0.021

+ 0.030

0
+ 0.060

0
+ 0.042

0
+ 0.060

- 0.079
- 0.109
- 0.218

- 0.040
- 0.053
- 0.106

- 0.072
- 0.086
- 0;172

0.040
0.072
DESIGN
0.079
CLEARANCE - 0.139
0.074
0.116

~,

/"

1
F

t-

50

~
+ 0.012
+ 0.007

F
38.1

G
2C

+ 0.025

+ 0.1 ~21

0
+ 0.050

0
+ 0.1 42

- 0.030
- 0.045
- 0.090

- 0.1 65
-0. 17
- 0.~ 34

0.030
0.065
- 0.070 - 0. 38

PUMP TYPE : GH-RlT-214, GH-RlT-H 8

14
P 17 / 34

6. Causes of trouble and cc untermeasures

S'

Trouble
Defective
rotation

;::$

p.

.....0
s:l

.o0t<:$
...,

Sudden stop
during
operation

Cause
1. Installed mproperly.
2 .Rotors bit ~ foreign objects.
3 .Assemble( improperly.
1. Rotors hi e foreign objects.
2 .Seized or leformed by heat.

::-.
0

z
No liquid
pumped up

Liquid pumped
up at low
::-.
p. pressure
rJl
rJl
<!)

~
<!)
......

1.Thepump is rotating in the

reverse di ection.
2 .The suctio n valve is closed.
3 ;Air leaks ir..
4 .The viscos 'ty of the liquid is
too high.
1 .Liquid is 1: ypassed in the
piping.

2 .Cavitation

rJl

s:l

3 .Increase o leakage in the

pump

Abnormal vibration
and noise

1 .Motor
2 .Shaft coup ing
3 .Wear ofpo wer and idler
rotors
4 .Foreign ob 'ects bite
5 .Relief valv ~ is hunting.
6 .Cavitation
7 .Others

Fluctuations of
pressure

1 .Cavitation
2 .Relief valv is hunting.
3 .Air in pipii g
4 .Others

Leakage

1 .Seal is fitte d improperly.

2 .Seal wears excessively.

Countermeasure
1 .Realign the pump and the motor
2 .Remove foreign objects and clear the
inside of the pump.
3 .Reassemble the pump.
1 .Repair a minl)r flaw: If a flaw is 1arge,
replace the damaged part.
2 .Repair or replace the damaged p rt.
Inspect the past operation such ~ s
dry running, cavitation, sudden ise
of discharge pressure, chimge in
temperature, etc.
1 .Reverse the wiring of the motor.
2 .Open the suction valve.
3 .Repair equipment where air leak ~in.
4 .Decrease the viscosity of the liqu d.
1 .Re-adjust the relief valve and the
pressure regulating valve.
Inspect whether liquid is leaking ~rom
other parts.
2 .If the liquid has too high viscosit' ,
decrease the viscosity of the liquid.
If air is taken in, repair the place
where air is taken in.
3 .Measure the dimensions of screw ,a
sleeve and bearings. If wearing iE
over the limit, replace the parts.
Confirm that the viscosity of the
liquid meets the specification.
1 .Inspect the motor to see if it is
overloaded.
2 .Inspect the alignment of the shaft
coupling. Inspect the wearing.
3 .Measure the dimensions of the
parts. If the wearing is over tt. e
limit, replace the parts.
4 .Repair or replace.
5 .Check the parts of the valves. If t ere
is excessive gap, replace them.
6 .Refer to the item [Cavitation] abo V'e.
7 .Inspect the foundation and the pi ing
to see if vibration and noise come
from them.
1 .Refer to the item [Cavitation] abo e.
2 .Adjust set pressure till the relief
valve stops hunting.
3 .Adjust an air. ventilation valve.
4 .Inspect whether the fluctuations cf
pressure are affected by other par s.
1 .Disassemble and reassemble the
pump
2 .Replace the seal with a new one.

15
P 18 / 34

7. Disassembling and reas ~embling

Understan the content of the instruction manual thoroughly
before any ~ork.
Take the p oper method and use the proper tools. Replace the
used parts N"ith the new parts made by the original suppliers.

CAUTION

Cut off the witch of heat source to decrease temperature to the

normalleve1 before inspection or maintenance.
Depressuri2 e the pump and the piping to ~he atmosphere level
and confirm the pressure before disassembling.
Disassembl 3 or reassemble the equipment by licensed or
authorized personnel with sufficient knowledge. Fix hanging
wire to the ~eavy weight equipment after studying the gravity
center and he weight.
Dispose a p ~mp casing, an attachment valve, an exchange part,

NOTICE oil and fat a s the general industry rejection

The following points are impo iant for the safety during disassembling the pump.
1. Cut off electricity suppl y.
2. Confirm the teinperatu e of pump casing to be the normal temperature.
3. Prepare a chain or a ch 1in block for lift and a container to collect liquid in the
pump.
4. Do not damage mechan cal sea~.
5. Do not damage surface pf rotating parts such as a power rotor, idler rotors,
bearings, etc.
7. 1 Disassembling( see SECTIPNAL ASSEMBLY)
(1) Close the valves on t ~e suction side and the discharge side to cut off t P,e
liquid supply.
(2) Disconnect the piping irom the pump. (When the motor is re~oved from t 1e
common bed, the pump an be disassembled with the piping connected.)
(3) Remove the pump and or the motor from the common bed.
(4) Draw out the shaft co 11pling and the key(103) from the power rotor(101) JY
using tool such as a gea puller or the like.
(5) Remove the seal cover(5 J8) and take out the oil seal.
(6) Remove the cover(521) and take out the mechanical seal(520) and the b~ 11
bearing(540).

Remove the casing cov ~r(002) by screwing the jack bolts into the casing cov ~r
evenly.
(8) Take out the power rot pr(101) and idler rotors(121) together.
(9) Remove the rear cover 004). Take out the bearing seat(255) by turning to t e
opposite direction of the pump rotation.
(7)

Do not remove the sleeve(2 H) unless it is replace with a new one.

16
P 19 / 34

7. 2 Reassembling (See a~~<~""''u SECTIONAL ASSEMBLY)

Reassembling
are backward procedures of disassembling.
damage the sealing p
such as 0-ring, mechanical seal, packing, etc.
reassembling. Apply
lubricating oil to the surface of the bearings
Do not allow any foreign objects get
mechanical seals before

the pump.
(1) Install the rear
the pump casing(001) with the
matching each other.
(2) Clean the power
1) and idler rotors(121) with clean oil, insert
into the sleeve(20 1)
the numbers carved on the rotors matching
other (see Figure 6).
(3) Attach the ball u"<:~L.LuJ~,u"J:v' to the power rotor(101).
(4) Assemble the
seal(520) and attach-to the power rotor(101).
(5) Replace the cover(52
(6) Replace the seal
._ .."""'J' after the oil seal attached.
(7) Clean the key(103)
the shaft coupling(302) to remove rust and burr,
apply lubricant (such as grease) to the parts. Fix the key and the
coupling to the
rotor without bending the shaft or damaging
bearings.
(8) Rotate the power
with hands to check the smooth rotation.
(9) Mount the pump and
motor on the common bed and align them.
Ball Bearing
Be a

Cover

Oi I Sea I

Rear Cove

Front S de
Figure 6.

17
P 20 / 34

GHS02!55fi2\IGHSU.:l45:l1>

I BIBLIOGRAPHY

103) (538) (520) (524) (521) (522

!Xl
(202'

121

101)

(001

ot::;j

~~s

ooaQ

Mechanical Seol

8t'"'

ALLOWABLE LEAKAGE ' 3mllh

MAKER : PILLAR

TYPE : MC3-DF40

,/

1-'

00

532)

(543) (54 2)

rs..:o

0048
I

I
I

------------- --------------------------------~--------------

~= :::-::::-:::-:: :~-::::.:: ::.::::;:,:: ;:,={1: :t: :-::::

~~~[!:~---'i'l.r---------------------------

t--t-

5388
5218
0048
0028
543
542
540
538
532
524
522
521
520
257
256
255
202
121
.103
101
071
070
032
0::11
004
002
001

Hexagon Heod Boll

Hexagon Heod Boll
Hexagon Heed Boll
Hexagon Heed Boll
Bearing Nut
Bearing Washer
Boll Bearing
Seal Cover

P 21 / 34

I
-j---r,
I

I
-

,---f-----------~

I
---- --- _

Carbon
Carbon
Carbon
Carbon
Beorino

Steel
Steel
Steel
Steel
Steel

Carbon Steel

ll.
ll.
.!!
1
1
1
1
1
1
1

Mechanical Seal

s..oi

I PBC2
I SUJ2
IP8C2

Bearing Seal
Throat Bush

Phosphor Bronze
Bearing Sleel
Pho_~<>r Bronze
L@oded Bronze

I LBC2

flu:tile ~on

Idler Rotor

Key

o Ring

Carbon Steel
Carbon Steel
Rubbr
Carbon Steel
Rubt>r

0 Ring

Rubber

Rear Cover

Carbon Steel
Carbon Steel
Cas! Iron

I FCD55
I S45C
I S45C
I NBR
I SS400
INBR
NBR
I SS400
I SS400 I
I FC200 I

Thrust

Batonce Piston

Power Rotor

o Ring
Orcin' Tube

Casing Cover
Casing

NAME OF
ARTICLES

NAME
I JIS
MATERIALS

1: 1 APPRO\r,t'~ ,~1-MAIN
..

111!1

.?_

ps G 5502-'61

1
~

.?_

1
1
1
1
1
1

WORKING IREHARKS
No.

SEAL OIL PUMP

f-*.17/:.....w -

~~~~~~~ /DESIGNIS.Fviii~ l=.:c~l SECTIONAL

~

SS400
SS400
SS400
SS400
SS400
SS400
SUJ2
SS400
NBR
SS400
NBR
SS400

Carbon Steel

Carbon Steel
Rubber

cover

CHECK

,l

Corban Steel

Carbon Steel
Rubber

Oil Seal
Spring Seal
0 Ring

REF.
No.

orL TANK

t-0

--...... -- ...

ASSFMRI V

~<"-'"'*,-!--f::'-=+----l DR~~.NG

ISCALE

I GHS035562

i=:}s s I .........._ ,_,tiitf161q 11M.

BASE

TOKYO

.JAPAN

___ ,

-~-----

;--

GHS0.355613 tGHS0~914l

I BIBLIOGRAPHY

103) (538) (520

524) (521

t:<.j

522

~'I

(/)

I~

pj

L-

zQ

(/';l

t_::!:j

Mechanical Sect

ALLOWABLE LEAKAGE ' 3mllll

MAKER , PILLAR
TYPE ' MC3-0F40

./

......

532

543'

""qc '!
~

5386'

5213

t:

--1-~~,______,....
)
OIL TANK

!' ~

------------~~-------------

----------------------------

===-=-~----:-:..--~~-=-=-=-=-=-=-=-=====-=-=

~J

P 22 / 34

I I

II

tt--r
I

'-=--"1---=-::.-=-=- 1--+-

0046

538B Hexagon Head Ball

Carbon Steel
lr.
5218 lii>>QQOO He!ld
0046 Hexagon Head Boll Carbon Steel
0026 Hoxagon Hood Boll
Corban Steel
Bearing Nut
543
Carbon Steel
Bearing Washer
542
Carbon Steel
Boll Bearing
540
Beorino Steel
Seal COver
538
Corban Steel
Oil Seal
532
Rubber
Spring Seat
524
Carbon Steel
0 Ring
522
Rubber
Carbon Steel
521
Cover
Mechanical Seal
520
Phosphor
Bronze
Thrust
Seat
257
Bearing Steel
Balance Piston
256
Bearil!S_ s~at
255
Phosohor Bronze
Leaded Bronze
Throat Bush
202
121
Idler Rotor
Ductle Iron

"''

_lo~_

~y___ ------

101
071
070
032

Power Rotor
0 Ring
DrcinTube
0 Ring
0 Ring

031
004
002
001

Rear Cover

Casing Cover
Casing

. REF.
No.

NAME OF
ARTICLES

!ill~

:<l

-r---,,
I

CHECK ,

lil!l~

SS400
SS_400
55400
S5400
SUJ2
SS400
N6R
SS400
N6R
SS400

8
8

PBC2
SUJ2
PBC2
LBC2
FCD55

-~-OJ!l!lO_~~e~-- ~'L
Corban
Rubber
Corban
Rubber
Rubber
Carbon
Carbon

Steel
Steel

Steel
Steel

Cost Iron
NAME

S45C
NBR
SS400
NBR
NBR
55400
SS400
FCZO!:
JIS

MATERIALS

:o~'<=P-'"

DESIGN I H!;/:>.

'i:i

c:::

~
1-t:::i

1
1
1
1
1
1
1
1
1
2

2
1
1
2

!Js G 5502-'61

-+-+----2

1
1
1
1
1

1
WORKING I REMARKS
No.

~~~~~ SECTIONAL

DRAWN I sFujila
k1

rufF')._
~

,.,,""

APPROVE~'~'""':MERGENCY SEAL OIL PUMP

_,f<!

~ASS

---

SS400I

~""'

DATE IHAR-2420091

DR~~-ING

SCAtt.

I GHS035563

~~l.ml.
TOKYO

..JAPAN

ITS

----~~-~~~----

----

--------"--

lll161!f9MOo

Re!cCrd of Chango:s

tDi'71 I

Chcg=

IJ,"J'

~I("

-;?7

:1-

..;

-f ").~~- ~

Hs.

rrtt\11\ ~

--------------------+H-ir---t-~1~

\j !

1:...:>

2XM10

11.2

MOTOR SIDE

~\

I,J

.I(Gl

2XM10 _

PUMP SIDE

223.5
WASHER2
WASHER!

S:25C

NUT

ssac

BOL't

4
3

E!.BMENT

B
B
2
l

SCM435
SUSSD4

B45C

ITEM

.f-o

111

IP..
;)

EQUIPMENT'S
1/AME

SPEC

I.TEM

MAIN SEAL
OIL PUMP

.
G~

7.5 kW.
1450 min-1
49.4 Nm

MDIDR
SPEED
IURQUE

ORDAT

SPEC
245 Nm

1
2.2 mm
2.8 mm 10')

....!AXIAl.
0..

83 N/mm

:::>

111

MAKER
NAUE

I
I

DAIOO-PRECIS!ON

0
0

INOUSTRIES,LID.

WITHIN 0.25mm /G

2.SPHERICAL FACES OF THIN &

THICK WASHERS SHALL BE
FACED TO THE ELEMENTS.

Al>IIICORROSION

COli

~etru;iptlan

P 23 / 34

. nr:.

"'LlJ" ...

I'UIJ Mf'

DC.

_"'=:!J

U..

U..

DURABLE 10 TIMES IN USE.

1116

S25G

S45C
l
M.:sterio
rra _ II II

_ .... d

&
TOSHIBA/ XIT03/04

!XIDE

lf8 X 1.0
MB X 1.0

S45G

KOSAKA lABORATORY LID.

co
0
3.FASTEN THE BOLTS PROPER
co It)
It)
TORQUE WITH TORQUE WRENCH 1.1")
(")
I
PROPER TORQUE: 22 Nm
C'? ~
.~

SPACER
HUB 2
HUB
I

..... ...... A
eu..stcmr"u Ndr'J6
co

fORIHLEX

COUPUNG

NOTE:ASSEMEUNG INSTRUCTIONS
1.THE DISTANCE BETWEEN FLANGE
FACES SHALL BE ADJUSTED

!!;n-F

YCAB201567

Dai4B Precision lndustrles Ltd.

~v

t -'

~r-o

-.___J_____:.

~z
r-o

./

(D)~5

140

50

+-

-z
r.tJ.

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I '
. ""F"'

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&,1JUN.22.200

. --Renrrks

l~rl
~ame~

FORM-FLEX COUPUNGS

AB-20-P~-42KP/3BKP

-140.

~. ~-b~/~

:k:li!!I~'MI!S!flli;;;!:~:M:

r =-ri''

,-,---,

80
'i:l

2
0

U'1

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H

t""'

,_..

!>:)

'i:l

NOTE~SEMBUNGINSTRUCTIONS

UllE DISTANCE BETWEEN FlANGE

FACES SHALL BE ADJUSTED

Wf"IN 0.25mm /G
2.SPHERICAL FACES OF THIN &: !

THICK WASHERS SHALL BE

FACED TO THE ELEMENTS.

IIAI.[

! . ! .. -J!lt.

. I . I --- I

~a;-rptiOri

i!'l:i ~..... "!!'~.!~~

RI11CII'kii

P 24 / 34

FL XIBLE DISK COUPLING

IN TRUCTION MANUAL

recision n ustr1es
FFICE & SALES OFFICE
3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME
TOSHI A-KU, TOKYO JAPAN 171-0021

FAX: 81-3-5956-9177

P 25 / 34

This manual details the align ent and assembly of type AX, A4, AB, AS anq A6 4bolt couplings. Reasonable care in initial assembly and alignment will ssure
couplings operate at full c pacity, compensate for misalignment, and p ovide
unlimited service life.

1. Coupling Alignment
(1) Inspect shafts and hub bores and ensure they are free from burrs or defec s.
(2) Check for proper fit of key to shafts and hubs ..
(3) After hubs are bored for i terference fit, they should be heated in oil at 90- 20 C
and then quickly installe on the shaft. Do not spot heat as this may ause
distortion.
CAUTION: GLOVES SHO LD BE WORN DURING THIS INSTALLATION
PROCEDURE.
(4) Insert the shaft in the hub so that shaft end is aligned with the end plane
hub. (Fig. 1)

f the

Flg.1

(5)

Driver and equipment m st be installed in the proper position. The dis ance
between flanges should b set within the allowable range of 0.5 mm.
(6) Angular Misalignment (Fig. 2)
(a) Install a dial gauge on ne hub as shown in Fig. 2, rotate the same hub, note
the minimum indication f the dial gauge, and set gauge to zero .
. (b) Rotate the coupling on which the dial gauge is installed, 360 and djust
position of the connect d equipment until the indicator reading is within 0.05;
mm.

recision Industries Ltd.

HEAD

FFICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKt:rnO 3-CHOME

-KU; TOKYO JAPAN 171-0021 .
TOSHI

PHONE: 81-3-5 56-9176

FAX: 81-3-5956-9177

P 26 / 34

I
Fig.2

(7) Parallel Misalignment (Fig. 3)

(a) Install the dial gauge on the driving side hub and check for p rallel
misalignment (Fig. 3). Rotate the coupling on which the dial gauge is
installed, 360 and a just height of the connected equipment until. the
indicator reading is with n 0.1 mm.
(b) Recheck angular misa ignment and paralell misalignment and ensur they
does not exceed the all wable misalignment.

Fig. 3

2. Assembly
Flexible disk couplings are assembled by various methods (the relation betwee the
assembly location of bolts and reamer holes). Each coupling is designed to be fee of
defects from the viewpoint of st ength and performance irrespective of whether bolts
are tightened from the hub or sp cer side. However, two bolts are tightened from both
the hub and spacer side, respec ively on the individual flange planes in principle. Be

/lJl

Daido recision Industries Ltd.

HEAD FFICE & SALES OFFICE
TOS

S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME

-KU, TOKYO JAPAN 171-0021

PHONE: 81-3-5 56-9176

FAX: 81-3-5956-9177

P 27 / 34

careful not to force these bolts

easily from the spacer side. Als
due to interference of bolts, if the
In such case, insert all bolts fro
procedure.

rom the spacer side since bolts cannot be ins rted

the coupling flanges cannot always be disasse bled
inter-axis size (D) is smaller than specified in T
the hub side while observing the following ass

CAUTION: AS THESE CO PLINGS USE NYLON NUTS WHICH CANNO BE

USED FOR DISASSEMBLY AN ASSEMBLY MORE THAN 10 TIMES, REP ACE
NUTS AS REQUIRED.
2.1 When the inter-shaft size is arger than specified in Table 1;
Insert two bolts through relief hoi son both hub and spacer sides, respectively.

Size

05
10
15
20
25

Table 1
D (mm)
Size

D (mm)

65
70
86
95 .

127
142
162
176

113

30

35
40
45
50
55

199

246

(1) Install thick washer (2) on ach bolt with its curved surface facing the thre d so
that the curved surface tau hes the element to be assembled later.
(2) Assemble the element by inserting two bolts into the relief holes of hu A.
Install thin washer (1) on e ch of. these bolts with is curved surface touchin the
element, and install the w sher on the bolt threads slightly protruding fro the
element surface. (Fig. 4)

Flg.4

g}l

Daido recision Industries Ltd.

HEAD 0 FICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO T BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME

TOSHI
-KU, TOKYO JAPAN 171-0021

PHONE: 81-3-59 6-9176

FAX: 81-3-5956-9177

P 28 / 34

(3) Insert bolts into the relief ales of hub B, and assemble the element by th
procedure as described i (2), and then, install washers (1).
(4} Install the spacer betwee hubs A and 8; (Fig. 5)

same

Fig. 5

(5) Insert the assembled bot s in hubs A and B into the spacer side reamer holes
after aligning them with e ch other.
(6} Install nuts on each bolt, nd tighten .them lightly. (Fig. 6)

Fig.6

Now, hubs A, B are temper rily assembled on the same shaft together wi h the
spacer.
(7) Insert bolts from the relief holes an the spacer side with the washe s (2}
previously installed, install thin washer (1) on each between the element an hub
with its curved surface t uching the ele.ment after these bolts have p ssed
through the element. (Fig. 7)

1/Jl Daido Precision Industries Ltd.

HEAD

FFICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME

TOSH
-KU, TOKYO JAPAN 171-0021

PHONE: 81-3-5 56-9176

FAX: 8135956-9177

P 29 / 34

Fig. 7

(8) Install nuts from the hub side, and tighten them lightly.
(9) After the above assembly tighten the installed bolts at diagonal positions

venly
and alternately. Ensure hat the tightening torque of all bolts meets the alues
specified in Table 2. No , assembly is completed.

CAUTION : CHECK AND RE DJUST THE DECLJNA TION, MISALIGNMENT, AND

TIGHTENING TORQUE OF C UPLING BOLTS, ONE OR TWO HOURS A ER
STARTING OPERATION TOP OLONG COUPLING LIFE.

Table 2
Size

Width across flats

of bolt head (mm)
Fastening torque
(N-m)

05

10

15

20

25

30

35

40

45

50

55

10

10

13

13

17

19

19

24

24

27

36

22

22

41

72

72

160

160

220

570

2.2 When the inter-shaft size D is smaller than specified in Table 1;

Insert all bolts from the hub side.
(1) Insert two bolts into hub . reamer holes. Install thin washer (1) on eac
with its curved surface fac ng the threads so that the curved surface touch
element to be assembl d later, and then, assemble the element
recommended to install e ch bolt into the element while turning it, and th
can be inserted correctly long its threads. Push the bolts through the hu
the threads slightly protru e from the element surface. (Fig. 8)

UJb Daido
HEAD

bolt
s the
It is
bolt
until

recision Industries Ltd.

FFICE & SALES OFFICE

3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME

TOSH
-KU, TOKYO JAPAN 171-0021

PHONE: 81-3-5 56-9176

FAX: 81-3-5956-9177

P 30 / 34

Fig. 8

(2) Insert each bolt into hu 8 reamer hole, and assemble thin washer (1) and
element in the same way s described in (1 ).

recision Industries Ltd.

FFICE & SALES OFFICE
3-FL. NISHI-IKEBUKURO S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME
TOSHI
-KU, TOKYO JAPAN 171-0021

PHONE: 81-3-5 56-9176

FAX: 81-3-5956-9177

P 31 / 34

(3) Install the spacer betwee hubs A and B. (Fig. 9)

Hub

---t-1-+H-t-

(4) After aligning the bolts as embled on hub A with the relief holes of the s

insert bolts toward the sp cer side.

(5) Install thick washer (2) on each hub A bolt from the spacer side with its c rved
surface touching the elem nt, and tighten it lightly with the nut.
(Fig. 10)
(6) Insert the bolts assemble on hub B into the relief holes of the spacer in the
same way as described in (4).
(7) Install thick washer (2) fro the spacer side onto each of hub B bolts, and install
nuts in the same way as d scribed in (5).

.-

Fig.10

Now, hubs A and B are temporarily assembled on the same shaft togethe with
the spacer.
(8) Install thick washer (2) on each of all residual bolts with its curved surface
touching the element, and insert the element from the relief hole of the hub
(9) Install thin washer (1) b tween the element and the spacer with its c rved
surface touching the elem nt on each bolt. (Fig. 11)

UlJ

Daido recision Industries Ltd.

PHONE:

FFICE & SALES OFFICE

S BUILDING, 1-15 NISHI-IKEBUKURO 3-CHOME
TOS
-KU, TOKYO JAPAN 171-0021
81-3-5956-9176
FAX: 813~5956-9177

P 32 / 34

Fig.11

(1 0) Install nuts from the spa er side, and tighten them lightly.
(11) After the above assem ly, tighten the bolts installed at diagnonal positions
nsure thatthe tightening torque of all bolts mee s the
evenly and alternately.
values specified in Table 2. Now, assembly is completed.
CAUTION : CHECK AND RE DJUST THE DECLINATION, MISALIGNMENT, AND
TIGHTENING TORQUE OF C UPLING BOLTS ONE OR TWO HOURS A ER
STARTING OPERATION TO PR LONG COUPLING LIFE.

recision Industries Ltd.

FFICE & SALES OFFICE
3FL. NISHIIKEBUKURO TS BUILDING, 1-15 NISHHKE:BUKURO 3-CHOME
TOSHI
-KU, TOKYO JAPAN 171-0021

PHONE: 81359 6-9176

FAX: 8135956-9177

P 33 / 34

TOSHIBA

:It

El

KCO 03085-a

REVISAL RECORD

33 FINAL
~

-~~ft13

REV.

REV. ISSUED

>er. -7 -~o

............................
PAGE

....

~!l!fii pfi .& {tp;j ~

*i~

~:lt

CH NGED PLACE AND CONTENT

APPROVED BY

REVIEWED ~y

Initial Issue

~g~
PREPARED BY

~ fjlt1~J..'
H-~~
~.-8~vo se,,-J- ~Q
~p.- q'1o ~

P 34 / 34