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Repair and Maintenance

fIELD Training
for DP/DPF Pumps
Pump Cut-Away
Special protection
from water ingress

Standard – with 1.35


Service Factor Rugged motor housing

Thermal sensor in
motor windings
Progressively Stacked Slurry Lip Seals
Standard on DPF15 thru DPF150B Models
Heavy-Duty Mechanical Seal
Standard on DP3 thru DP10 Models
Optional on DPF15 thru DPF75 models First response moisture sensor
Standard on DPF15 thru DPF150
Optional on DP3 thru DP10 Models

Front (adjustable) and Back


Toyo’s Unique High Chrome Agitator
High Chrome Wear Plates
Pump Bearings
What we will be covering today on
your DP/DPF pumps:
• How to set impeller clearance
• Potting Cables
• Megging Cables
• Installation: Slurry Lip Seals
• Troubleshooting Tips
• Lubrication
Setting Impeller
Clearance
Remove Agitator & Suction Strainer
Adjust the clearance between the front
wear plate (impeller disc) and the
impeller to .040” - .060” (1.0 - 1.5 mm) Set Nut
Adj. Bolt

To adjust the impeller, loosen the set nuts and move the impeller disc towards the impeller
using the adjustment bolts. Move the impeller disc until it just touches the impeller (the impeller
can still be rotated by hand with a slight drag). Be careful not to over tighten this as you can
damage the impeller disc.

Turn the bolts in the opposite direction ¾ of a turn to lower the suction plate approximately
1mm (0.040”). Then tighten the impeller disc set nuts.
Potting Cables
Part # Description Mix Ratio
119182 Elan Cast Black E805 Resin 4 parts
117864 Elan Cast C3341 Hardener 1 part

VIDEOS
Wire Preparation
Set Ring Packing
Cable Placement
Wire Separation
Megger Test

Remove the resin by drilling holes in the resin to weaken


it and then break it with a screwdriver or chisel.
Megging Cables
The following procedure is how to perform the megger check insulation resistance of the
motor and cable.

1. Disconnect the power cable from the power source


2. Verify continuity between the cable ground and the motor frame
3. Test the motor and cable assembly. Using the 500 VDC Megger
Tester, check the electrical insulation resistance between the cable
ground conductor (green) and each power conductor in turn.
4. Any reading less than 1 meg-ohms indicates damage to the power
cable and/or the motor.
5. If the reading is less than 1 meg-ohm, disconnect the
power cable from the motor and megger test the insulation
resistance of the motor itself in the same manner as above.
6. If all motor readings are more than 10 meg-ohms, this
indicates a problem in the cable and requires immediate
replacement of the cable.
7. Any motor reading less than 10 meg-ohms indicates
damage to the motor in which case the motor must be
checked by a qualified motor shop.
Progressive
Lip Seal
Installation

Shaft Sleeves
Rareflon Lip Seals
Nitrile Lip Seal
Troubleshooting
There is a whole section in the manual on trouble shooting, here are a few key points:

Pump won’t start


- The motor is burned out or is burning out
- The cable has been incorrectly wired to the starter.

Pump requires excessive power


- Specific gravity of the liquid is higher than the design SG.
- Total system head lower than pump design resulting in too much flow.
- Impeller clearance too tight
- Insufficient submergence of the motor (motor running hot).

Low flow rate or insufficient head


- Impeller is excessively worn and needs to be replaced our adjusted
- The discharge pipe or suction strainer is partially clogged.
- The discharge hose is kinked
- The motor direction is reversed
Troubleshooting continued…

Excessive noise and vibration


– The bearings are worn or damaged and needs to be replaced
– Operating near shut-off (very low flow rate)
– Insufficient or incorrect grease in the bearings
– Impeller loose or damaged causing imbalance
– Impeller vanes clogged

Lip seals have short life


– Shaft sleeve worn or badly scored
– Incorrect type of lip seals
Lubrication
LUBRICANT CHECK
Check lubrication oil level in oil reservoir at least every
500 operating hours or monthly.

1. Set the pump horizontally on appropriate wooden


blocks with one of the oil covers facing up.
2. Remove the oil cover and angle the pump allowing
some oil to drain slightly to check the consistency.

CAUTION: Be aware of the pump’s weight and its


center of gravity when moving to prevent serious
accidents or damage.

If the oil is milky white or has water mixed in with


it, replace the oil (See next slide for details)

3. Inspect the seal on the oil cover and replace if


damaged.

4. Check oil within a few days to confirm oil is still


clear. If the oil is cloudy, the pump may require
disassembly for replacement of the shaft seal.
DP/DPF - Lubrication Table

Pump DP 3-2 DP 7.5-2, DPF 15 DPF 30 DPF 50 DPF 100B


Model: DP 5-2 DP 7.5B-2, DPF 20 DPF 30B DPF 50B
DP 10-2 DPF 20B DPF 75
DP 10H-2 DPF 75B

PROGRESSIVE Not Not 4.1 Liters 5.9 Liters 6.2 Liters 25 Liters
LIP SEALS: Applicable Applicable (1.1 US Gal) (1.56 US Gal) (1.6 US Gal) (6.6 US Gal)

MECHANICAL 2.2 Liters 2.6 Liters 3.3 Liters 4.7 Liters 5.0 Liters 25 Liters
SEAL: (0.58 US Gal) (0.69 US Gal) (0.87 US Gal) (1.24 US Gal) (1.3 US Gal) (6.6 US Gal)
Oil Replacement
1. Set the pump horizontally on appropriate
wooden blocks with one of the oil covers
facing up. Remove both oil covers and
drain oil.

Note: Used oil should be appropriately


disposed of by waste disposal contractors in
compliance with local regulations.

2. If water (milky white oil) and sludge have contaminated the oil reservoir, check the shaft
seals and lower bearing and replace as necessary.
3. Replace the seals on the oil covers
4. Re-install the lower oil cover
5. Re-fill the oil to the quantity in the table. (previous slide)
Oil Replacement

5. Use the following oils:


Pumps with lip seals ISO Grade
#100 turbine oil (or non-detergent
SAE 30 if turbine oil unavailable)
Pumps with mechanical seals
ISO Grade #32 turbine oil (or non-detergent
SAE 10 if turbine oil unavailable)
6. If pump is run intermittently, the oil
reservoir should be examined more often.
7. If the pump has not been operated for a
long period of time, the oil reservoir should
be examined shortly after startup to ensure
there has been no deterioration of seals.
Check the Pump
Rotation!!

Bump start the pump.

Check the direction of rotation is


counterclockwise when viewed from
the suction end