Operating manual
MAXA CN
BA.223.CNY.001.12/07.GB
HILGEDOCUMENTATION
Declaration of conformity
in accordance with EC Machine Regulation 98/37/EC1
MAXA CN
is in compliance with the following requirements:
• Directive 98/37/EC
(Machine Directive, Appendix II A)
• Directive 73/23/EEC
(Low-Voltage Directive, Appendix III B)
• Directive 89/336/EEC
(EMC Directive).
December 2007
Heinz Rust
Director of design
1. This declaration of conformity in combination with the CE symbol applies only to pumps with motor.
Introduction HILGEDOCUMENTATION
1. Introduction
Abstract
This section describes the requirements which are important for reading and understanding this manual. You will
learn the symbols and formats that make the reading easier.
It is assumed that all such personnel will have the basic tech-
nical background required for the start-up, maintenance and
repair of pump systems.
1.2 Symbols and formatting The following symbols and formats are intended to make it
easier to read this document:
• Listed items
Instructions Instructions that must be carried out in a specific sequence
are numbered in the corresponding order.
*
Important information and helpful tips are identified with the
index finger symbol.
Safety instructions The system used to identify safety instructions is described in
section 2.3 .
Copyright This document may not be copied, translated into other lan-
guages or made available to third parties without our explicit
written approval.
Technical changes Design variants, technical data and spare part numbers are
subject to technical change.
The right to make changes for the sake of further technical de-
velopment is reserved.
BA.223.CNY.001.12/07.GB 5
HILGEDOCUMENTATION Safety
2. Safety
Abstract
This section describes what you have to consider for your own safety. You will learn the structure and identifica-
tion of safety instructions. Read this important section attentively!
2.1.1 General information All our pumps are professionally packed before they leave our
warehouse to avoid damage during transport.
Unpacking If, after carefully unpacking and inspecting the shipment, you
however find damage, you must promptly inform the shipping
agent (railway, post office, lorry driver, shipping line, etc.).
Your claim should be filed with the shipping agent. The ship-
ping risk passes to the customer as soon as the shipment
leaves our warehouse.
Read safety instructions! The operating manual contains all basic information required
for the setup, operation and maintenance of the pump. The in-
staller as well as the technical personnel or operator respon-
sible for the pump must therefore read this manual before
installing and starting the pump. The operating manual must
always be available at the site where the machine/system is
being used. Not only the general safety instructions present-
ed in this section but also the specific safety instructions in lat-
er sections must be followed.
Signal words In order to classify the safety labels they are distinguished by
the following signal words:
6 BA.223.CNY.001.12/07.GB
Safety HILGEDOCUMENTATION
• DANGER
Characterises an imminent hazard with a high risk which
can cause death or grievous bodily harm.
• WARNING
Characterises a possible hazard with medium risk which
can cause death or bodily harm if it is not avoided.
• CAUTION
Characterises a hazard with minor risk which can cause
minor or medium bodily harm if it is not avoided.
Do not remove instructions from machine Instructions attached directly to the machine, such as rota-
tional direction arrow, must be noted and kept in completely
legible condition.
2.4 Qualifications and training of The employees operating, maintaining, inspecting and install-
personnel ing the pump must have the appropriate qualifications for this
work. The operator must define in detail the tasks for which
the employees are responsible, the tasks of which they are in
charge and the manner in which they are supervised.
2.5 Hazards upon failure to follow If these safety instructions are not followed, employees, the
the safety instructions machine itself and the environment will be in danger.
BA.223.CNY.001.12/07.GB 7
HILGEDOCUMENTATION Safety
Warning
Burn hazard from hot or cold mechanical components.
Warning
Trapping hazard!
Danger
Danger generated by contact with or by inhaling hazard liq-
uids, exhalations or steams.
Warning
Tripping hazard from electric power cable.
8 BA.223.CNY.001.12/07.GB
Safety HILGEDOCUMENTATION
Danger
Electrical hazard! Danger of electrical shock from contact with
energised components.
2.9 Improper operation The operational reliability of the delivered machine can be
guaranteed only when it is used properly as indicated in the
following sections.
*
The given limit values may not be exceed under any circum-
stances.
2.10 Transport
Warning
Falling loads are dangerous!
Caution
Using incorrect lifting points is dangerous!
BA.223.CNY.001.12/07.GB 9
HILGEDOCUMENTATION Safety
K.0113V1
Fig. 2 Attachment points for CN pumps (example)
2.11 Cleaning CIP and SIP methods must be in accordance with the latest
current guidelines of the EC.
Warning
Danger from pressure surge! Liquids under high pressure can
be forcibly ejected from the pump.
10 BA.223.CNY.001.12/07.GB
Safety HILGEDOCUMENTATION
2.12 Repair contract The duty to follow the legal regulations on work safety and the
regulations on environmental protection means that all com-
mercial enterprises must protect their employees, the public
at large and the environment from the harmful effects of haz-
ardous materials.
BA.223.CNY.001.12/07.GB 11
HILGEDOCUMENTATION Description
3. Description
Abstract
This section describes the pump as well as its design and application. The section „Technical Data“ describes
limits for application. You must know and keep these limits.
K.0263V1
Fig. 3 Overview of MAXA
• industrial application
• textile technology
• surface treatment for environmental technologies
• all systems and processes involved in the food product,
dairy and beverage industries.
12 BA.223.CNY.001.12/07.GB
Description HILGEDOCUMENTATION
Warning
Improper usage is dangerous.
3.3.1 Pumped liquids Only pure or slightly contaminated liquids with a maximum
particle size of 0.4 mm may be pumped. These liquids may
not chemically or mechanically attack the pump materials or
lower their strength. If liquids with a viscosity greater than that
of water are to be pumped, make sure that the motor will not
be overloaded. The pump may not be operated beyond the
maximum allowable values. Even short periods of pressure
overload (e.g. as a result of a pressure surge) should be
avoided.
3.3.2 Minimum flow rate Qmin Do not operate the pump below a minimum flow rate of
Qmin = 10 - 15 % Qopt.
3.3.3 Connections and pipelines The nominal diameters of the system pipelines should be
equal to or greater than the nominal diameters of the pump,
i.e. DNE (suction side) and DNA (pressure side), and the con-
necting elements to the pump must conform exactly to the de-
sign standard/specification of the mating connector piece
installed on the pump. The suction line must be absolutely
leak-tight and laid in such a way that no air pockets can form.
Avoid tight elbows and do not install valves immediately up-
stream of the pump. The suction head of the system may not
be greater than the suction head guaranteed by the pump.
3.3.4 Motor activation Do not start and stop the motor more than 15 times per hour.
3.3.5 Design All information and descriptions in this operating manual con-
cerning the use and operation of the pumps are based exclu-
sively on the standard designs.
BA.223.CNY.001.12/07.GB 13
HILGEDOCUMENTATION Description
Warning
Danger of overloading the pump!
3.4.1 Pump denomination The HILGE pump denomination is structured as shown be-
low:
3.4.2 Pump serial number The pump can be identified by the pump serial number. When
ordering spare parts, always state the pump serial number.
14 BA.223.CNY.001.12/07.GB
Description HILGEDOCUMENTATION
3.4.3 Nameplate The nameplate is shown in fig. 4 and contains the following
data:
Pump -Type
1
K.0109V2
No. 2
Q 3 m3/h H 4
P 5 kW n 6 min -1
Doc. -No.
7
MADE BY HILGE
Fig. 4 HILGE nameplate, example
• 1 - pump type
• 2 - pump serial number
• 3 - capacity Q
• 4 - head H
• 5 - motor power P
• 6 - drive speed n
• 7 - number of operating manual
NOTE: The nameplate can deviate from the one shown.
3.4.4 Performance data The performance data of the pump, namely its head and de-
livery rate, are determined in accordance with
DIN EN ISO 9906 - appendix A, class 2, and are documented
on the acceptance records.
Caution
It is dangerous to exceed the maximum operating tempera-
ture!
BA.223.CNY.001.12/07.GB 15
HILGEDOCUMENTATION Description
Warning
Pressure overload is dangerous!
Pump operating pressure The maximum permitted operating pressure depends on var-
ious factors:
• pump type
• design of connections
• design of mechanical seal.
For the values that apply to your pump, please refer to the or-
der documents.
16 BA.223.CNY.001.12/07.GB
Mounting, installation and connection HILGEDOCUMENTATION
4.1.1 Check failure-free running of the Check the failure-free impeller running in this way:
impeller
1. Remove motor shroud1.
2. Remove fan cover of motor.
3. Consider direction of rotation (arrow).
4. Rotate shaft slowly by hand via the fan.
The shaft must rotate easily. If the impeller rubs against the
pump casing (for example due to transport damage), it has
been damaged.
Warning
Danger of misalignment of the pump due to an improper foun-
dation.
BA.223.CNY.001.12/07.GB 17
HILGEDOCUMENTATION Mounting, installation and connection
Warning
Electrical danger due to short circuit!
Why is alignment important? Careful alignment significantly increases the service life of the
coupling as well as the shaft bearing and sealings.
Warning
When aligning the coupling, pay close attention to safety in-
structions in section 2.2.
18 BA.223.CNY.001.12/07.GB
Mounting, installation and connection HILGEDOCUMENTATION
S2 max
Ka
A
K.0159V1
S2 min
S2 max
B Kw
S2 min
Kr
C
Fig. 5 Types of shift (principal figure)
• A - axial shift
• B - angular shift
• C - radial shift
4.4 Permissible shift values Never under any circumstances exceed the following shift
Flender H / HDS coupling values of the coupling during operation.
Design H and HDS The following table contains a list of coupling designations
and drill hole diameters.
1. For vertical pump setup (CNV), place the underlay plates between the pump casing and vertical frame.
BA.223.CNY.001.12/07.GB 19
HILGEDOCUMENTATION Mounting, installation and connection
Design H and HDS The following tables contain lists of permissible values for ax-
ial shift.
4.4.3 Angular shift UKw Angular shift UKw is useful to measure as the difference of
gap dimension (US2=S2max - S2min). Permissible values
for the gap dimension may be seen in tab. 5.
4.4.4 Radial shift UKr The following table lists permissible shaft shift values for radi-
al shift UKrzul and the difference for gap dimension US2zul
(zul = German abbreviation for "permissible").
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Mounting, installation and connection HILGEDOCUMENTATION
4.5 Permissible shift values ROTEX Never under any circumstances exceed the following shift
DKM values of the coupling during operation.
4.5.1 Design Rotex DKM Note for reading 6 and 7: To determine the deviation values,
always select the smaller shaft diameter of the shaft pair to be
connected.
Standard coupling
Shaft diameter 14 19 24 28 38 42 48 55 65 75
Max. axial shift U Ka [mm] 1.0 1.2 1.4 1.5 1.8 2.0 2.1 2.2 2.6 3.0
Max. radial shift U Kr [mm] with 0.17 0.20 0.22 0.25 0.28 0.32 0.36 0.38 0.42 0.48
n=1500 min-1
Max. radial shift U Kr [mm] with 0.11 0.13 0.15 0.17 0.19 0.21 0.25 0.26 0.28 0.32
n=3000 min-1
Max. angular shift U Kw [degrees] with 1.2 1.2 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2
n=1500 min-1 (0.67) (0.82) (0.85) (1.05 (1.35) (1.7) (2.0) (2.3) (2.7) (3.30)
Max. angular shift U Kw [degrees] with 1.1 1.1 0.8 0.8 0.8 0.8 0.9 1.00 1.0 1.0
n=3000 min-1 (0.62) (0.70) (0.75) (0.84) (1.10) (1.40) (1.60) (2.00) (2.30) (2.90)
BA.223.CNY.001.12/07.GB 21
HILGEDOCUMENTATION Mounting, installation and connection
Warning
Danger of mechanical overload!
Caution
Danger of mechanical overload due to closing caps or foil!
22 BA.223.CNY.001.12/07.GB
Mounting, installation and connection HILGEDOCUMENTATION
To seal the pump shaft against the pump casing, the mechan-
ical seal needs lubrication between its rotating faces.
0433.00
K.0173V2
P A
L
Fig. 6 Lubrication between sliding surfaces
• P - pump side
• 0433.00 - mechanical seal
• L - lubrication
• A - atmosphere side
Caution
Danger of dry running!
BA.223.CNY.001.12/07.GB 23
HILGEDOCUMENTATION Mounting, installation and connection
K.0076V2
P M
P M
4.7.1 Double mechanical seal HILGE pumps with double mechanical seal are equipped with
a seal cartridge.
A
K.0246V1
0491.00
24 BA.223.CNY.001.12/07.GB
Mounting, installation and connection HILGEDOCUMENTATION
Caution
Danger of dry running!
BA.223.CNY.001.12/07.GB 25
HILGEDOCUMENTATION Mounting, installation and connection
• preventing leaks
• dry-run protection
• lubrication and cooling of the mechanical seals
• cutting off the air from substances which react unfavoura-
bly with oxygen.
A pure liquid, compatible with the pumped liquid, serves as a
flushing liquid.
Warning
Danger of electric shock!
Warning
Danger of capacity overload!
26 BA.223.CNY.001.12/07.GB
Mounting, installation and connection HILGEDOCUMENTATION
L1 L2 L3
U1 V1 W1
K.0079V1
W2 U2 V2
L1 L2 L3
U1 V1 W1
K.0080V1
W2 U2 V2
Caution
Danger of dry running!
BA.223.CNY.001.12/07.GB 27
HILGEDOCUMENTATION Start-up / shutdown
5. Start-up / shutdown
Abstract
This section describes how to start up and shut down the pump. You get to know which inspections contribute to
failure-free operation and increased life of the pump.
5.1 Start-up
5.1.1 Check application conditions Check the application conditions of the pump in this way:
Caution
Danger of overheating and pressure overloading!
If delivery head does not rise after the pump has been
turned on:
28 BA.223.CNY.001.12/07.GB
Start-up / shutdown HILGEDOCUMENTATION
5.1.3 Functional check of mechanical seal Check the function of the mechanical seal in this way:
1. Watch the pump and check the mechanical seal for flaw-
less functioning (leak test).
An intact mechanical seal works virtually without leakage.
Caution
Danger of pressure surge!
What is a pressure surge? A pressure surge is an abruptly pressure increase in the sys-
tem. This pressure increase can - among other causes - be
caused by a quick blocking of the flow in the discharge pipe.
In case of a pressure surge, the maximum permitted pump
pressure is temporarily exceeded manifold.
Caution
Danger of jamming.
BA.223.CNY.001.12/07.GB 29
HILGEDOCUMENTATION Maintenance / servicing
6. Maintenance / servicing
Abstract
In this section you will get important information concerning maintenance and servicing the pump. Read this sec-
tion before you carry out maintenance work or troubleshooting measures!.
Warning
Danger of unprofessional work!
Warning
Danger of electrical shock, pressurized or hot components.
30 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION
Warning
Danger of hazardous substances!
Caution
Danger of frost!
Caution
Danger of improper tools!
6.2 Maintenance of the pump The pump is a low-maintenance pump. In addition to clean-
ing, the only point to be kept in mind is the wear to the rotating
mechanical seal.
6.3 Maintenance of the motor See the operating manual of the motor manufacturer.
BA.223.CNY.001.12/07.GB 31
HILGEDOCUMENTATION Maintenance / servicing
6.4.1.1 Cylinder bearing greases Use only the cylinder bearing greases listed here or demon-
strably comparable ones to lubricate the roller bearings.
Manufacturer Bearing temperature ≤120 °C Bearing temperature ≤60 °C – Danger of water entering
ARAL HL 3 FM 3
BP BP ENERGREASE LS 3 ENERGREASE PR 3
ENERGREASE LS 3
CALTEX CALTEX MULTIFAK 2 CALTEX CUP GREASE 3
CALTEX MULTIFAK 2
ESSO BEACON 3 ESTAN 2 R
BEACON 3
GULF GULFCROWN GULFCROWN
GREASE No. 2 GREASE No. 2
GULFCROWN GULFCROWN GREASE No. 3
GREASE No. 3
MOBIL - OIL MOBILUX GREASE No. 3 GARGOYLE
GREASE B No. 3
MOBILUX
GREASE No. 3
SHELL SHELL ALVANIA GREASE 3 SHELL UNEDO GREASE 3
SHELL ALVANIA GREASE 3
VALVOLINE VALVOLINE LB 2 VALVOLINE LB 2
OKS OKS 4200 (≤200 °C)
SKF LGMT 3/1 LGMT 3/1
Tab. 8 Cylinder bearing greases
6.4.1.2 Grease quantities for roller bearings The hollow areas between the cylinder bodies are factory-
during assembly filled 30% - 50% with grease. This grease filling is sufficient
for operation of the bearing under conditions normally en-
countered.
6.4.2 Bearing replacement To ensure problem-free operation of the pump, replace the
bearing after about 15,000 to 20,000 hours of operation.
6.4.2.1 Premature bearing replacement If persistent external conditions such as dust, splashed water,
aggressive ambient air or high temperatures promote wear,
bearings should be replaced after about 5000 hours of oper-
ation.
32 BA.223.CNY.001.12/07.GB
0970.00 0504.10 0330.00 0733.00 0932.02 0869.00 0840.01 0733.01 0800.00 0970.01
0360.00 0560.00 0321.00 0932.01 0517.01 0940.01 0904.01 0867.01 0681.00
6.5 Assembly
0902.01
BA.223.CNY.001.12/07.GB
0920.22
0934.03
6.5.1 Parts overview
0902.02
0920.04
0934.00
Maintenance / servicing
0518.01
0507.02
0940.00
0211.00
0507.00
0161.00
0901.23
0554.13
0902.02 0914.07 0504.00 0901.22 0183.00 0914.08 0904.00 0940.02 0890.00 0901.02
0920.04 0321.01 0518.02 0554.12 0901.21 0507.05 0840.00 0554.02
0934.00 0360.01 0867.00
K.0265V1
33
HILGEDOCUMENTATION
HILGEDOCUMENTATION Maintenance / servicing
Qty. Part no. Description Fig. Qty. Part no. Description Fig.
1 0102.00 volute casing 11 1 0840.00 coupling 11
1 0161.00 backplate 11 1 0840.01 coupling 14, 15
1 0167.00 casing backplate liner 14, 15 1 0867.00 coupling insert 11
1 0183.00 support foot 11 6 0867.01 coupling insert 11
1 0211.00 pump shaft 11 1 0869.00 coupling spacer 11
1 0321.00 grooved ball bearing 11 1 0890.00 baseplate 11
1 0321.01 grooved ball bearing 11 4 0901.21 hexagon head screw 11
1 0330.00 bearing housing 11 4 0901.02 hexagon head screw 11
1 0360.00 bearing cover 11 4 0901.21 hexagon head screw 11
1 0360.01 bearing cover 11 4 0901.22 hexagon head screw 11
1 0412.01 O-ring 46, 47 4 0901.23 hexagon head screw 11
1 0412.02 O-ring 14, 23, 39, 40 4 0901.29 hexagon head screw 23, 40
1 0412.35 O-ring 23, 40 12 0902.01 stud 11
1 0433.00 mechanical seal 11 12 0902.02 stud 11
1 0433.01 mechanical seal 11 4 0902.08 stud 14, 23, 39, 40
1 0471.00 seal cover 39, 40 1 0904.00 grub screw 11
1 0471.01 seal cover 11 1 0904.01 grub screw 11
1 0491.00 seal cartridge 14, 23, 39, 40 1 0904.02 grub screw 23
1 0504.00 spacer ring 11 4 0914.07 socket head cap screw 11
1 0504.09 spacer ring 14, 15 4 0914.08 socket head cap screw 11
1 0504.10 spacer ring 11 4 0914.09 socket head cap screw 39, 40
1 0507.00 V-ring 11 12 0920.04 hexagon nut 11
1 0507.02 V-ring 11 4 0920.15 hexagon nut 14, 23, 39, 40
1 0507.05 V-ring 11 12 0920.22 hexagon nut 11
1 0516.00 locating ring 23, 39, 40 1 0932.01 circlip 11
1 0516.01 locating ring 15 1 0932.02 circlip 11
1 0517.01 shroud support ring 11 12 0934.00 spring washer 11
1 0518.01 nilos ring 11 12 0934.03 spring washer 11
1 0518.02 nilos ring 11 4 0934.11 spring washer 14, 23, 39, 40
4 0554.02 washer 11 4 0934.23 spring washer 11
2 0554.12 washer 11 12 0934.24 spring washer 23, 40
4 0554.13 washer 11 1 0940.00 key 11
4 0560.00 pin 11 1 0940.01 key 11
1 0681.00 coupling guard 11 1 0940.02 key 11
1 0733.00 pipe clamp 11 1 0970.00 plate 11
1 0733.01 pipe clamp 11 1 0970.01 plate 11
1 0800.00 motor 11
Tab. 9 Parts list for MAXA CN
Danger
Maintenance or assembly work can be dangerous if important
instructions are disregarded.
34 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION
Caution
For pump assembly, important aspects have to be taken into
account:
BA.223.CNY.001.12/07.GB 35
HILGEDOCUMENTATION Maintenance / servicing
Please note Unless specially noted in individual cases, the part numbers
given in the following instructions may be found in tab. 9.
K.0267V1
0940.00
0940.01
0518.02
0507.00
0360.01
0914.07 0914.08
0330.00 0183.00 0901.21
Fig. 12 CN bearing housing
1. Push the circlip 0932.01 over the shaft so that it 2. Press grooved ball bearings 0321.00 and
is positioned loosely between the two grooved 0321.01 onto shaft 0211.00.
ball bearings 0321.00 and 0321.01.
3. Mount spacing ring 0504.00. 4. Assemble circlip 0932.02.
5. Insert circlip 0932.01 into bearing housing 6. Guide grooved ball bearings 0321.00 and
0330.00. 0321.01 into the bearing seats.
To do this, push shaft 0211.00 from the motor
side far enough onto the backplate 0330.00 so
that you can insert the circlip 0932.01.
7. Optional: Insert Nilos disks 0518.01 and 8. Insert spacing ring 0504.10.
0518.02.a
9. Assemble the bearing cover 0360.00. 10. Assemble the bearing cover 0360.01.
To do this, use socket head cap screw 0914.07. To do this, use socket head cap screw 0914.08.
Torque: M6 - 8 Nm | M8 - 17 Nm Torque: M6 - 8 Nm | M8 - 17 Nm
11. Push the tip ring 0507.00 onto the shaft 0211.00. 12. Insert key 0940.01 into shaft 0211.00.
13. Optional: Push the shroud support ring 0517.01 14. Push the coupling half 0840.00 onto the shaft
onto the bearing housing 0330.00. stub.
15. Secure the coupling half 0840.00 with grub 16. Install support foot 0183.00.
screw 0904.00. To do this, use hexagon head screw 0901.21.
a. Optional - only for shaft Ø50 mm.
36 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION
K0247V1
C
A D
BA.223.CNY.001.12/07.GB 37
HILGEDOCUMENTATION Maintenance / servicing
K.0151V1
0504.09
0167.00
0161.00
Fig. 14 Single mechanical seal (A)
Please note The assembly aids listed here may be found on page 51.
1. At shaft diameter 30 mm and 40 mm: Insert the 2. Insert the O-ring 0412.02 into groove of seal car-
casing backplate liner 0167.00 into backplate tridge 0491.00.
0161.00.
3. Push mechanical seal cartridge 0491.00 into 4. Fasten seal cartridge 0491.00 on the backplate
backplate 0161.00. 0161.00. Use spring washers 0934.11 and hexa-
gon nut 0920.15 to do this. Torque:
M8 - 19 Nm.
5. Grease the centring between the backplate 6. Fasten backplate 0161.00 with seal cartridge
0161.00 and the bearing housing 0330.00. 0491.00 installed on the bearing housing
Use OPTIMOL Paste TA from Hilge assembly 0330.00.
tool kit (pos. 8, fig. 65).
7. Slide the assembly sleeve onto the shaft as far 8. Spray the assembly sleeve and shaft 0211.00
as the stop. with water.
Use spray bottle from HILGE assembly tool kit
(pos. 2, fig. 65).
9. Push the stationary ring of the mechanical seal 10. Push the rotating part of the mechanical seal
0433.00 into the seat. 0433.00 onto the shaft 0211.00 and as far as the
Use installation sleeve from HILGE assembly stop.
tool kit (pos. 12, fig. 65) to do this. Use installation sleeve from HILGE assembly tool
kit (pos. 12, fig. 65) to do this.
11. Push the spacing ring 0504.09 onto the shaft. 12. Pull the assembly sleeve from the shaft 0211.00.
38 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION
0504.09
K.0140V1
0433.00
0516.01
0167.00
Please note The assembly aids listed here may be found on page 51.
1. Slide the assembly sleeve from HILGE assem- 2. Spray the stationary ring of the mechanical seal
bly tool kit (pos. 3, fig. 65) onto the shaft exten- 0433.00 and the assembly sleeve with clean
sion. water.
Use spray bottle from HILGE assembly tool kit
* (pos. 2, fig. 65).
That way you avoid damages to the mechanical
seal during the further assembly.
BA.223.CNY.001.12/07.GB 39
HILGEDOCUMENTATION Maintenance / servicing
5. Push the rotating ring of the mechanical seal 6. Insert key 0940.00.
0433.00 onto the shaft 0211.00.
Use installation sleeve from HILGE assembly
tool kit (pos. 12, fig. 65) to do this.
Fig. 21 Key
40 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION
K.0251V1
0433.00
0412.35
0471.01
0901.29
0934.24
0516.00 0433.01
Fig. 23 Double mechanical seal tandem (C)
Please note The assembly aids listed here may be found on page 51.
1. Spray the stationary ring of the atmosphere-side 2. Place the stationary ring of the mechanical seal
mechanical seal 0433.01with clean water. 0433.01 in the seal cover 0471.01.
Use spray bottle from HILGE assembly tool kit
(pos. 2, fig. 65).
BA.223.CNY.001.12/07.GB 41
HILGEDOCUMENTATION Maintenance / servicing
5. Slide the assembly sleeve from HILGE assem- 6. Spray the rotating ring of the mechanical seal
bly tool kit (pos. 3, fig. 65) onto the shaft exten- 0433.01 with clean water.
sion. Use spray bottle from HILGE assembly tool kit
(pos. 2, fig. 65).
* 7. Push the rotating part of the mechanical seal
0433.01 onto the shaft 0211.00.
That way you avoid damage to the mechanical seal
during the further assembly. Use installation sleeve from HILGE assembly tool
kit (pos. 12, fig. 65) to do this.
42 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION
BA.223.CNY.001.12/07.GB 43
HILGEDOCUMENTATION Maintenance / servicing
0412.02
K.0152V1
0491.00
0914.09
0934.23
0471.00
0433.01
0412.01 0516.00
Fig. 39 Single mechanical seal back-to-back (D)
Please note The assembly aids listed here may be found on page 51.
1. Insert the O-ring 0412.02 into the seal cartridge 2. Fix the seal cartridge 0491.00 on the backplate
0491.00. 0161.00 by using the spring washers 0934.11
and the hexagon nuts 0920.15. Torque:
M8 - 19 Nm.
3. Push the backplate 0161.00 into the bearing 4. Slide the assembly sleeve from HILGE assembly
housing 0330.00 by using a plastic hammer. tool kit (pos. 3, fig. 65) onto the shaft extension.
*
That way you avoid damage to the mechanical seal
during the further assembly.
5. Spray the stationary ring of the atmosphere-side 6. Push the stationary ring of the mechanical seal
mechanical seal 0433.01 and the assembly into the seat of the seal cartridge 0491.00.
sleeve with clean water. Use installation sleeve from HILGE assembly tool
Use spray bottle from HILGE assembly tool kit kit (pos. 12, fig. 65) to do this.
(pos. 2, fig. 65).
7. Spray the rotating ring of the mechanical seal 8. Push the rotating ring of the mechanical seal
0433.01 and the assembly sleeve with clean 0433.01 in complete assembly onto the shaft up
water. as far as the stop.
Use spray bottle from HILGE assembly tool kit
(pos. 2, fig. 65).
9. Push the locating ring 0516.00 onto the shaft 10. Mount the rotating ring of the product-side
0211.00. mechanical seal 0433.00.
Use installation sleeve from HILGE assembly tool
kit (pos. 12, fig. 65) to do this.
11. Spray the stationary ring of the product-side 12. Insert the O-ring 0412.01 into the seal cover
mechanical seal 0433.00 and the assembly 0471.00.
sleeve with clean water.
13. Place the stationary ring of the mechanical seal 14. Fix the seal cover 0471.00 together with the sta-
0433.00 in the seal cover 0471.00. tionary ring of the mechanical seal 0433.00 on
the seal cartridge 0491.00 by using the spring
washers 0934.23 and the socket head cap
screws 0914.09. Torque: M6 - 8 Nm.
44 BA.223.CNY.001.12/07.GB
Maintenance / servicing HILGEDOCUMENTATION
0412.02
0491.00
0914.09
K.0153V1
0934.23
0412.35
0471.00
0934.24
0412.01 0901.29
0471.01
Please note The assembly aids listed here may be found on page 51.
1. Insert the O-ring 0412.35 into the atmosphere- 2. Slide the assembly sleeve from HILGE assembly
side seal cover 0471.01. tool kit (pos. 3, fig. 65) onto the shaft extension.
*
That way you avoid damage to the mechanical seal
during the further assembly.
3. Spray the stationary ring of the mechanical seal 4. Place the stationary ring of the mechanical seal
0433.01 with clean water. 0433.01 in the atmosphere-side seal cover
Use spray bottle from HILGE assembly tool kit 0471.01.
(pos. 2, fig. 65).
5. Push the atmosphere-side seal cover 0471.01 6. Push the rotating ring of the mechanical seal
onto the shaft 0211.00. 0433.01 onto the shaft 0211.00.
7. Slide the locating ring 0516.00 onto the shaft 8. Push the rotating ring of the mechanical seal
0211.00. 0433.00 onto the shaft 0211.00.
9. Fix the mechanical seal 0433.01 and 0433.00 10. Insert the O-ring 0412.02 into the seal cartridge
with the clamping screws on the shaft 0211.00 0491.00.
according to the correct position.
11. Fix the seal cartridge 0491.00 at the backplate 12. Fix the backplate 0161.00 to the respective drive
0161.00 by using the spring washers 0934.11 end parts.
and the hexagon nuts 0920.15. Torque:
M8 -19 Nm.
13. Fix the seal cover 0471.01 with the stationary 14. Insert the O-ring 0412.01 into the seal cover
ring of the mechanical seal 0433.01 at the seal 0471.00.
cartridge 0491.00 by using the spring washers 15. Insert the stationary ring of the product-side
0934.24 and the hexagon head screws 0901.29. mechanical seal 0433.00 into the seat of the seal
Torque: M6 - 8 Nm. cover 0471.00.
16. Push the seal cover 0471.00 onto the shaft 17. Fix the seal cover 0471.00 on the seal cartridge
0211.00 as far as the stop. by using the spring washers 0934.23 and the
socket head cap screws 0914.09. Torque:
M6 - 8 Nm.
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HILGEDOCUMENTATION Maintenance / servicing
6.6.7 Assembly of the impeller and volute Assemble the impeller and volute casing in this way:
casing
1. Insert key 0940.00. 2. Grease the impeller seat and the pump shaft
0211.00.
Use Klüberpaste UH1 96-402 from HILGE as-
sembly tool kit for this (pos. 6, fig. 65).
Fig. 41 Key
Fig. 43 Impeller
0922.00
0412.04
0230.00
A B A
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Maintenance / servicing HILGEDOCUMENTATION
7. Tighten the impeller nut 0922.00 by hand. Leave 8. Wet O-ring 0412.04 with clean water and slide it
about 5 mm space for the O-ring 0412.04.A over the impeller nut 0922.00 into the gap
between impeller nut 0922.00 and impeller
0230.00.A
Fig. 48 O-ring
A
) Applies to EPDM and Viton O-ring.
In case of other O-ring materials, insert O-ring into
impeller nut 0922.00 before the nut is screwed on.
9. Tighten the impeller nut 0922.00 by using the 10. For double mechanical seal tandem: Release
following torques: the spring of the rotating ring of the mechanical
• M20 - 100-120 Nm seal against the impeller 0230.00.
• M24 - 180-230 Nm
• M30 - 210-250 Nm
Fig. 51 Volute casing and bearing housing Fig. 52 Studs of volute casing
13. Assemble the volute casing 0102.00 and the 14. Tighten the hexagon nuts 0920.04 in the order
bearing housing 0330.00 by using the spring shown below.
washers 0934.00 and the hexagon nuts Torque: M10 - 37, M12 - 65 Nm.
0920.04.
1. 7.
5. 4.
3. 6.
8. 2.
BA.223.CNY.001.12/07.GB 47
HILGEDOCUMENTATION Maintenance / servicing
6.6.8 Assembly of coupling and motor Assemble the coupling and the motor in this way:
1. Slide the coupling half 0840.00 onto the shaft 2. Slide the coupling half 0840.01 onto the motor
0211.00. shaft.
Screw the grub screw 0904.00 one or two turns Screw the grub screw 0904.00 one or two turns
into the spacer coupling half 0840.00. into the coupling half 0840.01.
Fig. 55 Coupling half, pump shaft Fig. 56 Coupling half, motor shaft
3. Fix the support foot 0183.00 on the baseplate 4. Make sure the pump shaft 0211.00 turns
0890.00 by using washer 0554.12 and hexagon smoothly.
head screw 0901.22.
Tighten the hexagon head screw 0901.22 by
hand.
Fig. 61 Spacer
Fig. 62 Coupling, beveled steel edge
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Maintenance / servicing HILGEDOCUMENTATION
9. Tighten the screws of motor 0800.00, coupling 10. Assemble the coupling guard 0681.00 by using
0840.00/01, volute casing 0102.00 and support the support ring 0517.01 and the pipe clamps
foot 0183.00. See tab. 11 for the correct torques. 0733.00/01.
Check alignment of coupling again after doing
this. Correct it if needed.
6.7 Troubleshooting
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HILGEDOCUMENTATION Maintenance / servicing
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Maintenance / servicing HILGEDOCUMENTATION
6.9 HILGE assembly tool kit Remove and install the mechanical seals safely and reliably
by using tools of the HILGE assembly tool kit.
K.0266V1
Fig. 65 HILGE assembly tool kit
150-400 / 200-400
80-160
2 spray bottle • • •
3a assembly sleeve Ø 50 •
3b assembly sleeve Ø 40 •
3c assembly sleeve Ø 30 •
4a plastic adapter Ø 40 •
4d plastic adapter Ø 30 •
5 ejector for mechanical seal - stationary ring • • •
6 Klüberpaste UH1 96-402 • • •
7 socket wrench SW 32 •
7 socket wrench SW 50 •
7 plastic socket spanner insert SW 27 •
8 Optimol Paste TA • • •
9 socket wrench SW 27 •
10 screw locking Loctite type 243 • • •
12a mechanical seal installation sleeve with plastic adapter Ø 50 •
12b mechanical seal installation sleeve with plastic adapter Ø 38 and Ø 40 •
12c mechanical seal installation sleeve with plastic adapter Ø 28 and Ø 30 •
Tab. 13 HILGE-assembly tool kit, tools for MAXA
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HILGEDOCUMENTATION Certificate of non-objection
7. Certificate of non-objection
Abstract
This section contains a certificate of non-objection. In case of inspection or repairing, send the pump including
this certificate to HILGE.
7.1 Certificate of non-objection The following pump and its accessories, together with this
certificate of non-objection, are herewith contracted out by the
undersigned for inspection/repair:
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
The pump was carefully drained and also cleaned inside and
out before it was shipped/made available. (please mark with
a cross)
________________________________________________
________________________________________________
________________________________________________
________________________________________________
Company (address):
Telephone, fax, e-mail
Name (please print), title
Date
52 BA.223.CNY.001.12/07.GB
Certificate of non-objection HILGEDOCUMENTATION
BA.223.CNY.001.12/07.GB 53
HILGEDOCUMENTATION Certificate of non-objection
54 BA.223.CNY.001.12/07.GB
Service addresses HILGEDOCUMENTATION
8. Service addresses
Abstract
For questions and comments, please contact service addresses of companies below.
BA.223.CNY.001.12/07.GB 55