A. Decrease or loss of performance-check the following:
B. Leaks in the pump:
C. Excessive noise and vibration—check for the following:
D. Motor trouble:
A. Disconnect power source and drain the pump (34).
B. Remove stainless steel shroud (35) and six through bolts (37).
C. Remove porting turbine cover (36) and cylinder body (33). USE A RUBBER HAMMER TO TAP THEM APART rather than using a screw driver to pry them apart since this can crack the o-ring grooves and cause a leak.
D. Rotor removal (Carefully follow these steps):
E. Seal removal: Remove key (29), seal spring (24), and slide seal (24) off shaft.
F. Remove motor turbine plastic (22) by pulling it directly towards you. If it has a cracked o-ring groove or is worn, it must be replaced.
G. The stationary seat portion of seal (24) can now be pressed out of motor turbine plastic (22).
H. Remove the four motor turbine bolts (39), and remove motor turbine cover (21) from the motor or bearing housing if necessary to service these components.
A. Place motor turbine cover (21) on motor or bearing housing and bolt in position with the four motor turbine bolts (39). The two machined head bolts are used in the bottom holes. Use Loctite #242 on all threads.
B. Press stationary seat portion of seal (24) into motor turbine plastic (22) until it bottoms into bore. Motor turbine plastic must be replaced if it is cracked or worn. Some servicemen automatically replace this with the seal. Use P-80 THIX (International Products Corp.) glycerin, or a light machine oil (except donʼt use oil with EPDM elastomers) on elastomer cup and shaft side of bellows for easier installation. Donʼt touch sealing surfaces with fingers.
C. Place motor turbine plastic (22) in bored hole in motor turbine cover (21) and align locating lug. Take care when installing to avoid damage to stationary seat portion of seal (24).
D. Replace Shaft Seal: Slowly slide seal (24) on to shaft (use P-80 glycerin or light machine oil, except donʼt use oil with EPDM elastomers) until it touches stationary seat portion of seal. Donʼt touch sealing surface with fingers. Replace spring (24) and key (29).
E. Replace rotor: Push rotor (27) on shaft until adjusting setscrews (31) contact end of shaft. IF THEY HAVENʼT BEEN TOUCHED AS PREVIOUSLY INSTRUCTED THEY WILL PROVIDE PROPER CLEARANCE between the rotor (27) and porting turbine cover (36);
F. Replace o-rings (23) (new o-rings are recommended always), cylinder body (33), porting turbine cover (36), through bolts (37) and stainless steel shroud (35). NOTE: Be sure o-rings and all sealing surfaces are clean.
G. Then, tap lightly around the outside of the porting turbine cover (36) with a rubber hammer to seal it after assembly. “Cross Tighten” the six through bolts (37) equally to 6 foot pounds (72 inch pounds), with a torque wrench. This should provide the same clearance as set at the factory provided the shaft has not shifted as a result of a change in a bearing lock ring location.
Lyco Wausau, liquid ring vacuum pumps are among the easiest to field service if procedures in the section “Pump Disassembly and Shaft Removal”, are carefully followed, The main point is “DONʼT TOUCH THE TWO ADJUSTING SET SCREWS”. This is because they provide a locating point for clearance between the rotor (27) and porting turbine cover (36), and if they are disturbed, the clearance must be reset. Note that clearance must always be reset if the rotor, shaft (105) or close-coupled pump motor (40) are changed. Clearance of .005-.010 inches is basic to performance. If it is too wide, the pump will underperform. If it is too close, rubbing can occur and cause overheating and motor problems. The objective of the following STEPS, is to show how this can be done with reasonable precision. If optimum performance is unnecessary, and if the following repair tools are unavailable, contact the factory for instructions on abbreviated procedures.
Repair tools needed (see to “Parts List” page 23):
A. Partially assemble the pump with motor turbine cover (21), motor turbine plastic (22) and shaft seal assembly (24). See “Pump Assembly and Shaft Seal Installation” (page 13).
B. Before installing the rotor (27), remove the rotor retainer bolt (32), rotor set screws (28) and adjusting setscrews (31).
C. Install shaft key w/pin (29) and rotor (27) on the shaft. Install the rotor retainer bolt (32), and screw it in until the rear of the rotor is approximately 1/8 inch from the upper face of the motor turbine plastic (22). Use Loctite #242 on the bolt threads.
D. Place a dial indicator on the smooth part of the rotor face, rotate it 360 degrees to find the “high point”. Mark this point as instructed in figure 1.
A. Lay porting turbine cover (36) on face of rotor (27).
B. From the top of each port, take a depth micrometer measurement to the “high spot” determined in Step 1. Mark the locations from where these measurement were taken on the top of each port, since similar readings will be needed in STEPS 3 and 5. See figure 2.
Record the readings. We suggest they be written on the porting turbine cover (36) along side the port where each reading was taken. Use a pencil for easy erasing later.
|EXAMPLE:||Exhaust Port||Vacuum Port|
|STEP 2||1.100 Inches||1.050 Inches|
A. Assemble the remainder of the pump with the exception of the adjusting setscrews (31) and rotor setscrews (28) which will be installed later in STEP 4. Follow the instructions as described below:
B. Install cylinder body (33) with the drain connection positioned at the bottom-rear of the pump. Line up the six through bolt loops with corresponding six holes in the motor turbine cover (21), and use a rubber hammer to gently tap it down evenly over the motor turbine plastic (22) until it touches the o-ring all around.
C. Place the porting turbine cover (36) into the cylinder body (33) with its six through bolt holes lined up with corresponding loops on the cylinder body, and with the service liquid inlet lined up with the rotor retainer bolt (32). Use a rubber hammer to gently tap it down evenly all around into the cylinder body.
D. Insert the six through bolts (37) with the “castle head” nut ends facing the front. Use Loctite #242 on all threads.
E. Gradually “cross tighten” all of the through bolts (37) until the porting turbine cover (36) begins rubbing on the rotor (27). Determine this by periodically turning the rotor with a screw driver inserted through one of the ports.
F. Lower the rotor (27) on the shaft until it turns freely by turning down the rotor retainer bolt (32) with a 3/8 inch Allen wrench inserted through the 1/2 inch, service liquid primary inlet in the center of the porting cover (36), see page 5. Turn the retainer bolt until the rotor breaks free and turns when the retainer bolt is turned. Note that 1/10 turn will lower the rotor .008 inches.
G. Continue this procedure until the six through bolts (37) are all tightened to six foot pounds (72 in-lbs.) with a torque wrench, and the rotor (27) turns freely when it is turned completely around (360 degrees).
H. Tap lightly on the porting turbine cover (36) all around with a rubber hammer to be sure it is evenly set in the cylinder body (33). Recheck the torque on the through bolts (37), and tighten them if necessary.
I. Make a final check for rubbing by turning the rotor (27) completely around (360 degrees). If it is still rubbing, turn the rotor retainer bold (32) down again until the rotor breaks free and turns when the bolt is turned. At this point the clearance should be about .005 inches.
|Example:||Exhaust Port||Vacuum Port|
|STEP 3||1.106 inches||1.054 inches|
J. Determine clearance by taking two more depth micrometer measurements to the “high point”, one through each port, see Figure 3. Take these from the same locations marked on top of the ports in STEP 2. Record these readings with those from STEP 2, and calculate the differences which are the clearances. Note that clearances at each port are usually different due to tolerance variations in the pump.
The objective in STEP 3, is to have a clearance within the range of .005-.010 inches at the port where the “high point” is closest. A clearance on the low side of the range, as in this example, is desirable; however, if it is above the range, it can be lowered in STEP 4.
A. Partially disassemble the pump, including the through bolts (37), porting turbine cover (36) and cylinder body (33).
B. Set up the dial indicator again as shown in STEP 1, and set the dial to zero at the “high spot” so that any change in clearance can be measured. Be sure to have adequate travel on the indicator to accommodate adjustments that may be required.
C. Install the two adjusting setscrews (31) on each side of the rotor retainer bolt (32) and tighten them until they are snug against the end of the shaft. Use Loctite #242 on the threads.
D. If the clearance in STEP 3 is on the low side of the .005-.010 range, as in the example, tighten the rotor retainer bolt (32) to 62.5 foot pounds with a torque wrench, and observe the dial indicator reading.
E. If the clearance at any time is more than .010 inch, raise the rotor (27) by slightly backing out the rotor retainer bolt (32) and turning in the adjusting set screws (31). Note that 1/10 turn of the adjusting setscrews is .005 inches for &5hp pump models and .006 for the 7.5&10hp models. Observe the clearance changes on the dial indicator, and when the desired clearance is reached, tighten the rotor retainer bolt (32) to 62.5 foot pounds, using a torque wrench. Then install the rotor setscrews (28) and tighten to 19.2 foot pounds after using Loctite #242 on the threads.
A. Reassemble the pump. Be sure to “cross torque” the through bolts (37) to 6 foot pound (72 pound inches).
B. Turn the rotor (27) completely around (360 degrees) to be sure it isnʼt rubbing.
C. Recheck the clearance using the depth micrometer as in STEP 3. At this point, clearance should be within an acceptable range; however, if it isnʼt or if there is rubbing, STEP 4 should be repeated.
Lyco Wausau offers a special, factory, rebuilding program for Lyco owners. This work is done on an expedited basis, so turn around is fast. Some who have “standby” pumps prefer to send all of their Lyco pumps in for maintenance, while others use this service only for major repairs.
Having a standby pump can be advantageous for minimum downtime whether pumps are repaired in your shop or returned to the factory. Lyco owners can contact Lyco for special pricing on “standby” pumps.
Factory pricing for pump maintenance depends on what is required, but even with major repairs, it seldom reaches more than one half the price of a new pump. Rebuilt pumps carry a new pump warranty on all Lyco manufactured parts which are repaired or replaced. The procedure for using this service is as follows: