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MODEL A9 WITH DRYLOCK® II SEAL


Installation, Operation, Maintenance and Storage Manual

VISIT US AT
WWW .WILFLEY.COM

7350 E. Progress Place • Englewood, CO USA 80111 • Toll Free: 800.525.9930 • Phone: 303.779.1777 • Fax: 303.779.1277
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TABLE OF CONTENTS
FOREWORD......................................................... 1 5.0 OPERATION .................................................11
1.0 INTRODUCTION ............................................ 2 5.1 ROTATION CHECK ......................................11
2.0 SAFETY CONSIDERATIONS ........................ 2 5.2 PRE START-UP CHECKS ............................12
2.1 SAFETY TIPS ................................................. 3 Starting .......................................................12
Apparel ......................................................... 3 5.3 START-UP CONSIDERATIONS ...................12
Maintenance ................................................. 3 Ensuring Proper NPSHA ............................12
3.0 GENERAL INFORMATION ............................ 3 Minimum Flow ............................................13
3.1 STORAGE REQUIREMENTS ........................ 3 5.4 STARTING THE PUMP AND ADJUSTING
FLOW ...........................................................13
Long-Term Storage ...................................... 4
Pump Storage .............................................. 4 5.5 THERMAL SHOCK INSTRUCTIONS ...........14
Parts Storage ............................................... 4 5.6 OPERATION IN SUB-FREEZING
Motor and Seal Storage ............................... 4 CONDITIONS ...............................................14
3.2 HANDLING ..................................................... 4 5.7 SHUTDOWN CONSIDERATIONS................14
4.0 INSTALLATION .............................................. 5 6.0 PREVENTIVE MAINTENANCE ....................14
Inspection upon Arrival ................................ 5 6.1 GENERAL SERVICING ................................14
Choosing Pump Location ............................. 5 Motor ..........................................................14
Foundation ................................................... 5
6.2 PERIODIC SERVICING ................................14
Alignment ..................................................... 5
Piping ........................................................... 6 Need for Maintenance Records .................15
Discharge Piping .......................................... 6 Need for Cleanliness ..................................15
Suction Piping .............................................. 6 6.3 MAINTENANCE TROUBLESHOOTING .......15
Auxiliary Piping – Purge Piping .................... 6 ®
7.0 A9 WITH DRYLOCK II SEAL DISASSEMBLY
Piping Note ................................................... 6 & REASSEMBLY ..........................................19
4.1 FACTORY PRELIMINARY ALIGNMENT 7.1 DISASSEMBLY .............................................20
PROCEDURE ................................................ 6
Replacing the Bearings ..............................20
4.2 RECOMMENDED PROCEDURE FOR
BASEPLATE INSTALLATION AND FINAL 7.2 CLEANING/INSPECTION .............................21
FIELD ALIGNMENT ....................................... 6 7.3 CRITICAL MEASUREMENT AND
New Grouted Baseplates ............................. 6 TOLERANCES .............................................21
Alignment Procedure.................................... 7 Shaft ...........................................................21
Alignment Checks ........................................ 7 7.4 ASSEMBLY ...................................................22
Alignment Criteria......................................... 7 Impeller Clearance .....................................35
Dual-Dial Indicator Alignment Setup ............ 7 Standard A9 Pump .....................................35
Angular Alignment ........................................ 8 Dial Indicator Procedures ...........................35
Parallel Alignment ........................................ 8 Feeler Gauge Procedures ..........................35
Complete Alignment ..................................... 9 ®
DryLock II Seal Clearance Adjustment
Laser Alignment ........................................... 9 Procedures .................................................37
Alignment Troubleshooting ........................ 10
Existing Grouted Baseplates ...................... 10 7.5 ASSEMBLY TROUBLESHOOTING..............38
4.3 PIPING CONNECTION – Reinstallation ..............................................38
SUCTION/DISCHARGE............................... 10 7.6 TROUBLESHOOTING PUMP LEAKS ..........39
Suction Piping ............................................ 10 8.0 LUBRICATION ..............................................41
Discharge Piping ........................................ 11 Bearing Lubrication ....................................41
Pump and Shaft Alignment Check ............. 11 9.0 ORDERING PARTS .....................................41
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4.4 DRYLOCK II SEAL ...................................... 11 10.0 SPECIAL SERVICE ....................................42
4.5 MECHANICAL SEAL .................................... 11
4.6 COUPLING ................................................... 11
4.7 COUPLING GUARD ..................................... 11

7350 E. Progress Place • Englewood, CO USA 80111 • Toll Free: 800.525.9930 • Phone: 303.779.1777 • Fax: 303.779.1277
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FIGURES

Figure 1 – Bare Pump Lifting ..............................................................................................................................4


Figure 2 – Complete Pump Assembly Lifting .....................................................................................................5
Figure 3 – Pump and Baseplate Lifting ..............................................................................................................5
Figure 4 – Alignment – Two-Dial Indicator Method ............................................................................................8
Figure 5 – Pump with Rotation Direction Arrow................................................................................................12
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Figure 6 – A9 Pump with DryLock II Seal .......................................................................................................19
Figure 7 – A9 Frame Assembly ........................................................................................................................22
Figure 8 – A9 Shaft Assembly Step 1 ...............................................................................................................23
Figure 9 – A9 Shaft Assembly Step 2 ...............................................................................................................24
Figure 10 – A9 Shaft Assembly Step 3 .............................................................................................................24
Figure 11 – DryLock® II Style A1 For A9 Pump ...............................................................................................25
Figure 12 – DryLock® II Style A2 For A9 Pump ...............................................................................................26
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Figure 13 – A9 DryLock II Ball Assembly .......................................................................................................27
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Figure 14 – A9 Rotating DryLock II Assembly Step 1.....................................................................................28
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Figure 15 – A9 Rotating DryLock II Assembly, Step 2....................................................................................29
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Figure 16 – A9 Stationary DryLock II Assembly Step 1 ..................................................................................30
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Figure 17 – A9 Stationary DryLock II Assembly Step 2 – Varilip Configuration .............................................31
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Figure 18 – A9 Stationary DryLock II Assembly Step 2 – Wiper Seal Configuration .....................................31
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Figure 19 – A9 Complete DryLock II Assembly ..............................................................................................32
Figure 20 – A9 Complete Pump Assembly.......................................................................................................33
Figure 21 – Flush Configuration .......................................................................................................................34
Figure 22 – Dial Indicator Method (Preferred Method) .....................................................................................35
Figure 23 – Feeler Gauge Method ...................................................................................................................35
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Figure 24 – A9 DryLock II Seal Leakage Paths ..............................................................................................39
Figure 25 – Shaft Wrench Drawing ..................................................................................................................43

TABLES
Table 1 – Vertical Cold Settings Values .............................................................................................................7
Table 2 – Alignment Troubleshooting ...............................................................................................................10
Table 3 – General Recommendations for Minimum Continuous Flow .............................................................13
Table 4 – Recommended Service Checks .......................................................................................................15
Table 5 – Maintenance Troubleshooting ..........................................................................................................16
Table 6 – Casing and Impeller Clearances ......................................................................................................35
Table 7 – Assembly Troubleshooting ...............................................................................................................38
Table 8 – Acceptable Oils .................................................................................................................................41
Table 9 – Lubricating Oil Requirements ...........................................................................................................41
Table 10 – Approximate Oil Volumes ...............................................................................................................41
Table 11 – A9 Nominal Shaft Diameters ..........................................................................................................43
Table 12 – A9 Bolt Torque Values ....................................................................................................................44

7350 E. Progress Place • Englewood, CO USA 80111 • Toll Free: 800.525.9930 • Phone: 303.779.1777 • Fax: 303.779.1277
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FOREWORD
This manual provides instructions for the installation, operation, maintenance and storage of the Wilfley
Model A9 ANSI Standard Pump. This manual covers the standard product plus common options that are
available. For special options, supplemental instructions are supplied. This manual must be read and
understood before installation and start-up.

The design, materials and workmanship incorporated in the construction of Wilfley pumps makes them
capable of giving trouble-free service if properly applied and maintained. The life and satisfactory service of
any mechanical unit is enhanced and extended by correct application, proper installation, periodic inspection,
condition monitoring and careful maintenance. This instruction manual was prepared to assist operators in
understanding the construction and the correct methods of installing, operating, maintaining and storing
these pumps.

A.R. Wilfley and Sons, Inc. shall not be liable for damage or delays caused by a failure to observe
the instructions for installation, operation, maintenance and storage that are contained in this
manual.

Warranty is valid only when genuine Wilfley parts are used. Contact your local Wilfley
representative for basic warranty information and before making any changes.

Use of the equipment on a service other than stated in the order could nullify the warranty, unless written
approval is obtained in advance from A.R. Wilfley and Sons, Inc.

To assure proper installation, supervision from an authorized manufacturer’s representative is


recommended.

Additional manuals can be obtained by contacting your local Wilfley representative.

THIS MANUAL EXPLAINS

 Proper Storage
 Proper Installation
 Start-up Procedures
 Operating Procedures
 Preventive Maintenance
 Pump Overhaul
 Troubleshooting
 Ordering Spares or Repair Parts

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1.0 INTRODUCTION 3. Do not start a pump that is “wind-milling” in


the reserve direction due to fluid flowing
This manual contains instructions and guidelines back down the discharge pipe.
for the installation, operation, maintenance and
storage of the Wilfley A9 ANSI Standard Pump. 4. Do not continue to operate a pump when
there are indications that something is
There are many factors affecting the successful rubbing, binding or knocking.
installation, operation and maintenance of a
pump. From one pump to the next there is 5. Do not continue to run a pump that gives an
typically significant variation in these factors. This indication of overheating.
makes it impossible to create a bulletin that
covers all situations. 6. Do not operate a pump with the coupling
guard removed. Make sure the guard fits
Therefore, the information contained herein is snugly around the coupling so there are no
meant to serve only as a general guideline. If openings.
detailed questions or problems arise, contact the
Wilfley Sales Office or authorized 7. Do not operate a pump that is excessively
Distributor/Representative. vibrating, surging or making abnormal
noise.
It is extremely important that this entire
manual be read prior to installation or start-up 8. Do not work on a pump unless the drive
of the pump. system is locked out and the pump is
disconnected from the drive system.
This is important for safety, for proper
performance of the pump and for maximum Mean 9. Do not connect the pump to the drive
Time between Planned Maintenance (MTBPM). system without first checking to see that the
drive system is running in the correct
direction.
2.0 SAFETY CONSIDERATIONS
10. Do not rely on the factory’s alignment of the
Like all machinery, centrifugal pumps can be pump and the drive system. Alignment may
dangerous if used improperly. Any of the following have changed during shipment.
misuses may result in a pump that does not
function properly. A pump that does not function 11. Do not put a cold liquid in or on a hot pump
properly may be a hazard and could cause or a hot liquid in or on a cold pump.
damage or injury.
12. Do not hit a pump with any object.
For maximum safety and reliability, use only
factory-supplied parts and closely follow all 13. Do not use worn or faulty parts.
maintenance and operating recommendations and
instructions. 14. Do not stick hands, arms, legs or any other
object into the discharge, suction or any
Do not change the pumping conditions or other opening of a pump.
installations of a Wilfley pump without consulting
A.R. Wilfley and Sons, Inc. first to ascertain if the 15. Do not weld attachments to the pump.
pump is capable of handling the new conditions
and/or fluid. It is not possible to list all the 16. Do not apply external heat to the pump.
conceivable misuses. Therefore, the following list
is not meant to be complete and is provided only 17. Do not lift the pump by its case only.
as a guide of the types of misuse that can
damage a pump and cause injury. The list will 18. Do not examine a pump without using
also give a good idea of the kinds of misuses that proper eye and face protection.
will void any and all warranties.
19. Do not run equipment dry or start the pump
1. Do not run a pump with the discharge valve without the proper prime (Casing Flooded).
closed or below minimum rated flow.
20. Do not exceed the maximum allowable
2. Do not run a pump in the reverse direction. °
pressure (“Max. P. @ 38 C” as shown on
pump nameplate).

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The Wilfley A9 process pump has been designed 2.1 SAFETY TIPS
and manufactured for safe operation. In order to
ensure safe operation, it is very important that this
manual be read in its entirety prior to installing or
Apparel
operating the pump. Wilfley shall not be liable for
physical injury, damage or delays caused by a  Insulated work gloves when handling hot
failure to observe the instructions for installation, bearings or using bearing heater
operation and maintenance contained in this
manual.  Heavy work gloves when handling parts
with sharp edges, especially impellers
Remember that every pump has the potential to
be dangerous, because of the following factors:  Safety glasses (with side shields) for eye
protection, especially in machine shop
 Parts are rotating at high speeds. areas

 High pressures may be present.  Steel-toed shoes for protection when


handling parts, heavy tools, etc.
 High temperatures may be present.
 Other personal protective equipment to
 Highly corrosive and/or toxic chemicals may protect against hazardous/toxic fluids
be present.
Maintenance
Paying constant attention to safety is always
extremely important. However, there are often  Always lockout/tagout power.
situations that require special attention. These
situations are indicated throughout this book by  Ensure pump is isolated from system and
the following symbols: pressure is relieved before disassembling
pump, removing plugs, or disconnecting
piping.
! DANGER  Use proper lifting and supporting equipment
to prevent serious injury.
DANGER – Immediate hazards that WILL result in
severe personal injury or death.  Observe proper decontamination
procedures.

! WARNING  Know and follow company safety


regulations.

WARNING – Hazards or unsafe practices that  Never apply heat to remove impeller.
COULD result in severe personal injury or death.
 Observe all cautions and warnings

! CAUTION highlighted in pump instruction manual.

3.0 GENERAL INFORMATION


CAUTION - Hazards or unsafe practices that
COULD result in minor personal injury or product
or property damage.
3.1 STORAGE REQUIREMENTS

NOTE: ALWAYS COORDINATE REPAIR If the pump is inoperative for a long period of time,
ACTIVITY WITH OPERATIONS PERSONNEL it is recommended that the pump be flushed and
AND FOLLOW ALL PLANT SAFETY thoroughly dried to minimize corrosion. It is also
REQUIREMENTS AND APPLICABLE SAFETY advisable to drain the lines and case if there is a
AND HEALTH LAWS/REGULATIONS. possibility of freezing. If the pump is to be stored
for more than 15 days, the pump should be
rotated once a week to lubricate and to prevent
rusting of the bearings.

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Long-Term Storage
The following guidelines should be followed when
! CAUTION
the pump or parts will be idle for a period of one
month or more. Do not use eyebolts or cast-in lifting lugs to lift
pump, motor and baseplate assemblies.
Pump Storage
Before lifting the equipment, refer to the pump
data sheet for the complete assembly weight.
1. All machined metal surfaces should be
coated with a suitable corrosion inhibitor to
ensure the integrity of these surfaces at the Pump Components:
time of installation.
Casing: Use a choker hitch pulled tight around the
2. All openings must be covered with suitable discharge nozzle.
covers to protect against contaminants. Bearing frame: Insert a sling between the upper
and lower support ribs between the housing barrel
3. Storage of the Components and Assemblies and the casing attachment flange. Use a choker
should be kept away from all potential hitch when slinging. Caution: make sure there are
vibration sources. (i.e., motors, rotating no sharp edges on the bottom side of the ribs that
pumps, engines, etc.). This is to prevent could cut the sling.
unwanted vibration and possible brinelling
of the bearings. Bare Pump:

4. Components and assemblies are required Sling around the pump discharge nozzle and
to be stored indoors in a dry location. around the outboard end of the bearing housing
Temperature range should be between 40 with separate slings. Choker hitches must be used
degrees and 100 degrees Fahrenheit. If the at both attachment points and pulled tight. Make
environment is excessively humid (more sure the completion of the choker hitch on the
than 70%), a suitable desiccant should be discharge nozzle is toward the coupling end of the
used. pump shaft as shown in Figure 1. The sling
lengths should be adjusted to balance the load
5. Pump shafts are required to be rotated 5 full before attaching the lifting hook.
revolutions weekly to prevent brinelling.

Parts Storage
Not all parts are packaged in a suitable manner
from the factory for long-term storage. To ensure
satisfactory part performance, all parts must be
protected from corrosion and contamination.

Motor and Seal Storage


Refer to the manufacturer’s manuals for storage
instructions for these items.
Figure 1 – Bare Pump Lifting
3.2 HANDLING
The following describes how to lift pump
components, assembled pumps, or pump, motor
and baseplate assemblies. Do not attempt to lift a
pump mounted on a baseplate by itself.
A pump-motor assembly may only be lifted after it
has been installed on a baseplate. Lifting should
only be done by trained personnel. Pumps and
motors often have integral lifting eyes or eye bolts.
These are intended for use in lifting the individual
piece of equipment.

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Pump, motor and steel baseplate 4.0 INSTALLATION


assembly:
Inspection upon Arrival
Insert lifting S hooks in the lifting lugs and use
slings or chains to connect to the lifting eye as Your pump has been carefully inspected and
shown in Figure 2. Do not use slings through the tested prior to shipment to ensure that it meets
lifting holes. your requirements. Please inspect the pump upon
arrival for any damage that may have occurred
during shipment. Report any damage immediately
to the carrier.
Leave all shipping covers attached to the pump
unit until it is ready for installation. If installation is
to be delayed more than 15 days, the pump shaft
should be rotated by hand once a week to
lubricate the bearings and prevent rusting.

Choosing Pump Location


The following recommendations may be helpful
when choosing the best location for your pump:
Figure 2 – Complete Pump Assembly Lifting
1. Locate the pump as close to the liquid
Pump, motor and cast iron or source as practical so the suction pipe is
nonmetallic baseplate assembly: short and direct with a minimum of elbows,
fittings and valves.
Nonmetallic baseplates can easily be damaged in
handling. Be careful to handle the baseplate 2. Place the pump in a location so the unit is
gently and avoid any shocks. This assembly accessible for inspection during operation
utilizes a wooden shipping pallet that should be as well as for maintenance operations
left intact until final installation. The assembly involving removal and disassembly.
should be forklifted on the pallet to the installation
site and then removed only when ready to be Foundation
installed. Sling around the pump discharge nozzle
and around the motor-mounting end of the The foundation should be sufficient to absorb any
baseplate as shown in Figure 3. Choker hitches vibration and to form a permanent, rigid support
must be used at both attachment points and for the baseplate. This is important to maintain the
pulled tight. The sling lengths should be adjusted correct alignment of the direct connected unit. A
to balance the load before attaching the lifting concrete foundation on a solid base is
hook. Do not use slings through any lifting holes satisfactory. Foundation bolts of the proper size
and be careful not to damage the baseplate should be embedded in the concrete located as
material. indicated on the outline drawing.

Alignment
The pump and motor are aligned at the factory
before shipment. Realignment may be necessary
after the complete unit has been leveled on the
foundation and after the foundation bolts have
been tightened. Procedures for checking and
aligning the pump components are in section 4.2
of this manual and may also be found in the
Hydraulic Institute Standards.

Figure 3 – Pump and Baseplate Lifting

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Piping adequate space for workers to install,


operate and maintain the pump. The
Both suction and discharge pipes should be foundation should be sufficient to absorb
supported independently near the pump so when any vibration and should provide a rigid
the flange bolts are tightened no strain will be support for the pump and motor.
transmitted to the pump casing. The customer is Recommended mass of a concrete
responsible for proper suction and discharge pipe foundation should be three times that of the
design and layout to avoid flow induced problems. pump, motor and base.

Discharge Piping 2. Level the pump baseplate assembly with


the pump and motor on the baseplate. The
A valve should be installed in the discharge line to proper surfaces to reference when leveling
prevent fluid from flowing back through the pump the pump baseplate assembly are the pump
when it is shut down. The valve should block the suction and discharge flanges. DO NOT
discharge line during maintenance. stress the baseplate. Do not bolt the suction
or discharge flanges of the pump to the
piping until the baseplate foundation is
Suction Piping completely installed. If equipped, use
leveling jackscrews to level the baseplate. If
Care should be taken in sizing and locating jackscrews are not provided, shims and
suction piping to prevent cavitation. A valve wedges should be used. Check for
should be installed in the suction line to prevent levelness in both the longitudinal and lateral
fluid from flowing into the pump when it is shut directions. Shims should be placed at all
down. base anchor bolt locations and in the middle
edge of the base if the base is more than
Auxiliary Piping – Purge Piping five feet long. Do not rely on the bottom of
the baseplate to be flat. Standard baseplate
When required, purge piping is supplied with the bottoms are not machined, and it is not
pump. An external connection should be made at likely that the field-mounting surface is flat.
the pump so purge flow can be varied as required
by valving and the pressure can be monitored. 3. After leveling the baseplate, tighten the
Piping fittings and gauges must be corrosion anchor bolts. If shims were used, make sure
resistant to the fluid being pumped. that the baseplate was shimmed near each
anchor bolt before tightening. Failure to do
Piping Note this may result in twisting of the baseplate,
which could make it impossible to obtain
Refer to the Hydraulic Institute Standards for final alignment. Check the level of the
centrifugal pumps for additional piping baseplate to make sure that tightening the
information. anchor bolts did not disturb the level of the
baseplate. If the anchor bolts did change
the level, adjust the jackscrews or shims as
4.1 FACTORY PRELIMINARY needed to level the baseplate. Continue
ALIGNMENT PROCEDURE adjusting the jackscrews or shims and
tightening the anchor bolts until the
The pump and motor are aligned at the factory to baseplate is level.
verify the assembly.
4. Check initial alignment between the pump
4.2 RECOMMENDED and driver with a straight edge and correct
as needed.
PROCEDURE FOR BASEPLATE
INSTALLATION AND FINAL 5. Grout the baseplate. A nonshrinking grout
should be used. Make sure that the grout
FIELD ALIGNMENT fills the area under the baseplate. After the
grout has cured, check for voids and repair
New Grouted Baseplates them. Jackscrews, shims and wedges
should be removed from under the
1. The pump foundation should be located as baseplate at this time. If they were to be left
close to the source of the fluid to be in place, they could rust, swell and cause
pumped as practical. There should be distortion in the baseplate.

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6. Run piping to the suction and discharge of  After Connecting Piping – To ensure pipe
the pump. There should be no piping loads strains haven’t altered alignment. If changes
transmitted to the pump after connection is have occurred, alter piping to remove pipe
made. Recheck the alignment to verify that strains on pump flanges.
there are no significant loads.
Final Alignment (Hot Alignment)
7. Use the following procedure and set up the
final alignment between the pump and  After First Run – To obtain correct
driver. alignment when both pump and driver are at
operating temperature. Thereafter,
Step 8 follows the alignment section. alignment should be checked periodically in
accordance with plant operating
Alignment Procedure procedures.

Alignment Criteria
! WARNING Good alignment is achieved when the dial
indicator readings are specified in the alignment
Before beginning any alignment procedure make procedure as 002 in (.05 mm) Total Indicated
sure driver power is locked out Reading (T.I.R.) or less when the pump and driver
are at operating temperature (Final Alignment).
The points at which alignment is checked and
adjusted are: During the installation phase, however, it is
necessary to set the parallel alignment in the
 Initial Alignment is done prior to operation vertical direction to a different criterion due to
when the pump and the driver are at differences in expansion rates of the pump and
ambient temperature. driver. Recommended preliminary (cold) settings
for electric motor-driven pumps based on different
 Final Alignment is done after operation pumpage temperatures are listed in the following
when the pump and driver are at operating table.
temperature.
Table 1 – Vertical Cold Settings Values
Adding or removing shims under the feet of the Pumpage Temp Set Driver Shaft
motor and pump and by shifting equipment 50F (10C) 0.002 in (0.05 mm) LOW
horizontally as needed achieves alignment.
122F (50C) 0.001 in (0.03 mm) HIGH
302F (150C) 0.005 in (0.12 mm) HIGH
NOTE: Proper alignment is the responsibility of
the installer and user of the unit, not Wilfley.
Dual-Dial Indicator Alignment Setup
Accurate alignment of the equipment must be
obtained and sustained. Trouble-free operation 1. Mount two dial indicators on one of the
can be accomplished by following the proper coupling halves P so they contact the other
procedures. coupling half M.

2. Check setting of indicators by rotating


Alignment Checks coupling half P to ensure indicators stay in
contact with coupling half M but do not
Initial Alignment (Cold Alignment) bottom out. Adjust indicators accordingly.

 Before Grouting Baseplate – To ensure


alignment can be obtained.

 After Grouting Baseplate – To ensure no


changes have occurred during the grout
process.

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the shaft end (remove shims) or raising the


driver feet at the other end (add shims).

4. Repeat steps 1–3 until indicator A reads


.002 in (.05 mm) or less.

Horizontal Correction (Side to Side)


1. Zero indicator A on the left side of coupling
half M, 90 from top dead center (9 o’clock).

2. Rotate indicators through top dead center to


the right side, 180 from the start (3
o’clock). Observe needle and record
Figure 4 – Alignment – Two-Dial Indicator reading.
Method
3. Negative Reading – The coupling halves
Measurement are further apart on the right side than the
left. Correct by either sliding the shaft end of
1. To ensure accuracy of indicator readings, the driver to the left or the other end to the
always rotate both coupling halves together right.
so indicators contact the same point on Positive Reading – The coupling halves
coupling half M. This will eliminate any are closer together on the right side than
measurement problems due to runout on the left. Correct by either sliding the shaft
coupling half M. end of the driver to the right or the other end
to the left.
2. Take indicator measurements with driver
feet hold-down bolts tightened. Loosen 4. Repeat steps 1–3 until indicator A reads
hold-down bolts prior to making alignment .002 in (.05 mm) or less.
corrections.
5. Re-check both horizontal and vertical
3. Take care not to damage indicators when readings to ensure adjustment of one did
moving driver during alignment corrections. not disrupt the other.

Angular Alignment Parallel Alignment


A unit is in angular alignment when indicator A A unit is in parallel alignment when indicator B
(Angular Indicator) does not vary by more than (Parallel Indicator) does not vary by more than
.002 in (.05 mm) as measured at four points 90 .002 in (.05mm) as measured at four points 90
apart. apart at operating temperature. Note the
preliminary vertical cold setting table for values.
Vertical Correction (Top to Bottom)
Vertical Correction (Top to Bottom)
1. Zero indicator A at top dead center (12
o’clock) of coupling half M. 1. Zero indicator B at top dead center of
coupling (12 o’clock) half M.
2. Rotate indicators to bottom dead center (6
o’clock). Observe needle and record 2. Rotate indicator to bottom dead center (6
reading. o’clock). Observe needle and record
reading.
3. Negative Reading – The coupling halves
are further apart at the bottom than the top.
Correct by either raising the driver feet at
the shaft end (add shims) or lowering the
driver feet at the other end (remove shims).
Positive Reading – The coupling halves
are closer at the bottom than at the top.
Correct by either lowering the driver feet at

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3. Negative Reading – Coupling half P is


lower than coupling half M. Correct by
adding shims of thickness equal to half of
the indicator reading under each driver foot.
Positive Reading – Coupling half P is
higher than coupling half M. Correct by
removing shims of thickness equal to half of
the indicator reading from each driver foot.

NOTE: Equal amounts of shims must be


added to or removed from each driver
foot. Otherwise the vertical angular
alignment will be affected.

4. Repeat steps 1–3 until indicator B reads Figure 4 – Alignment – Two-Dial Indicator
within .002 in (.05 mm) or less when hot, or Method
per the vertical cold setting table values.
Vertical Correction (Top to Bottom)
Horizontal Correction (Side to Side)
1. Zero indicators A and B at top dead center
1. Zero indicator B on the left side of the (12 o’clock) of coupling half M.
coupling half M, 90 from top dead center (9
o’clock). 2. Rotate indicator to bottom dead center (6
o’clock). Observe the needles and record
2. Rotate indicators through top dead center to the readings.
the right side, 180 from the start (3
o’clock). Observe needle and record 3. Make corrections as outlined previously.
reading.
Horizontal Correction (Side to Side)
3. Negative Reading – Coupling half M is to
the left of coupling half P. Correct by sliding 1. Zero indicators A and B on the left side of
driver evenly in the appropriate direction. coupling half M, 90 from top dead center (9
Positive Reading – coupling half M is to o’clock).
the right of coupling half P. Correct by
sliding the driver evenly in the appropriate 2. Rotate indicators through top dead center to
direction. the right side, 180 from the start (3
o’clock). Observe the needle, measure and
NOTE: Failure to slide motor evenly will record the reading.
affect horizontal angular correction.
3. Make corrections as outlined previously.
4. Repeat steps 1–3 until indicator B reads
.002 in (.05 mm) or less. 4. Re-check both vertical and horizontal
readings to ensure adjustment of one did
5. Re-check both horizontal and vertical not disrupt the other. Correct as necessary.
readings to ensure adjustment of one did
not disrupt the other. Correct as necessary. NOTE: With experience, the installer will
understand the interaction between angular
Complete Alignment and parallel and will make corrections
appropriately.
A unit is in complete alignment when both
indicators A (angular) and B (parallel) do not vary Laser Alignment
by more than 0.002 in (0.05 mm) as measured at
four points 90 apart. This method can be used in place of the dual dial
indicator method. Please follow the instructions
given by the laser equipment manufacturer.

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Alignment Troubleshooting 4.3 PIPING CONNECTION –


Operate the pump for at least an hour or until it
SUCTION/DISCHARGE
reaches final operating temperature. Shut the
pump down and recheck alignment while the All piping must be independently supported,
pump is hot. Piping thermal expansion may accurately aligned and preferably connected to
change the alignment. Realign pump as the pump by a short length of flexible piping. The
necessary. See table below for possible alignment pump should not have to support the weight of the
issues. pipe or compensate for misalignment. It should be
possible to install suction and discharge bolts
Table 2 – Alignment Troubleshooting through mating flanges without pulling or prying
POSSIBLE RECOMMENDED either of the flanges. All piping must be airtight.
PROBLEM Pumps may air-bind if air is allowed to leak into
CAUSE REMEDY
the piping. If the pump flange(s) have tapped
Loosen pump hold
holes, select flange fasteners with thread
down bolts and slide
Driver feet engagement at least equal to the fastener
Can’t pump and driver until
bolt bound. diameter but that do not bottom out in the tapped
obtain horizontal alignment
holes before the joint is tight.
horizontal is achieved.
(side to Determine which
side)
alignment,
Baseplate corner(s) of the
not leveled baseplate are high or ! WARNING
angular or properly, low and remove or
parallel. possibly add shims at the
twisted. appropriate corner(s) Piping Forces:
and realign. Take care during installation and operation to
Can’t Determine if center of minimize pipe forces and/or moments on the
obtain Baseplate baseplate should be pump casing.
vertical (top not leveled raised or lowered and
to bottom) properly, correct by evenly Suction Piping
alignment, possibly adding or removing
angular or bowed. shims at the center of To avoid NPSH and suction problems, suction
parallel. the baseplate. pipe sizes must be the same or greater than the
pump suction connection. Never use pipe or
Existing Grouted Baseplates fittings on the suction that are smaller in diameter
than the pump suction size.
The ideal piping configuration should have a
When a pump is being installed on an existing
minimum of 10 pipe diameters between the
grouted baseplate, the procedure is somewhat
source and the pump suction. In most cases,
different from the previous section “New Grouted
horizontal reducers should be eccentric and
Baseplates.”
mounted with the flat side on top or up with a
maximum of one pipe size reduction. Never mount
1. Mount the pump on the existing baseplate.
eccentric reducers with the flat side down.
Horizontally mounted concentric reducers should
2. Level the pump by putting a level on the
not be used if there is any possibility of entrained
discharge flange. If not level, adjust the foot
air in the process fluid. Vertically mounted
piece by adding or deleting shims between
concentric reducers are acceptable. In
the bearing frame and baseplate.
applications where the fluid is completely de-
aerated and free of any vapor or suspended
3. Check initial alignment between the pump
solids, concentric reducers are preferable to
and driver with a straight edge and correct
eccentric reducers.
as needed.
Avoid the use of throttling valves and strainers in
the suction line. Start-up strainers must be
4. Run piping to the suction and discharge
removed shortly after startup. When the pump is
flanges of the pump.
installed below the source of supply, a valve
should be installed in the suction line to isolate the
5. Perform final alignment.
pump and to permit pump inspection and
maintenance. However, never place a valve
6. Recheck alignment after pump is hot.
directly on the suction nozzle of the pump. Refer
to the Centrifugal Pump IOM Section of the

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Hydraulic Institute Standards for additional 4.6 COUPLING


recommendations on suction piping.
The coupling should be installed as advised by
Discharge Piping the coupling manufacturer. Pumps are shipped
without the spacer installed. If the spacer has
Install a valve in the discharge line. This valve is been installed to facilitate alignment, then it must
required for regulating flow and/or to isolate the be removed prior to checking rotation. Remove
pump for inspection and maintenance. protective material from the coupling and any
exposed portions of the shaft before installing the
coupling.
! WARNING
4.7 COUPLING GUARD
A rapidly closing discharge valve can cause a
damaging pressure surge. A dampening
arrangement should be provided in the piping. ! WARNING
Pump and Shaft Alignment Check Power must never be applied to the driver when
the coupling guard is not installed.
After connecting piping, rotate the pump drive
shaft clockwise (view from motor end) several Wilfley coupling guards are safety devices
complete revolutions by hand to be sure there is intended to protect workers from inherent dangers
no binding and that all parts are free. Recheck of the rotating pump shaft, motor shaft and
shaft alignment. If piping caused unit to be out of coupling. It is intended to prevent entry of hands,
alignment, correct piping to relieve strain on the fingers or other body parts into a point of hazard
pump. by reaching through, over, under or around the
guard. No standard coupling guard provides
4.4 DRYLOCK® II SEAL complete protection from a disintegrating
coupling. Wilfley cannot guarantee its guards will
When the pump is intended to be equipped with a completely contain an exploding coupling.
®
DryLock II seal, it is Wilfley’s standard practice to The Wilfley coupling guard conforms to the U.S.A.
®
install the DryLock II seal in the pump prior to standard ASME B15.1, “Safety Standard for
shipment. Specific order requirements may Mechanical Power Transmission Apparatus.”
specify that the seal be shipped separately, or
none be supplied. It is the pump installer’s 5.0 OPERATION
responsibility to determine if a seal was installed.
If a seal was supplied but not installed, use the 5.1 ROTATION CHECK
seal installation instructions found in section 7.4.

4.5 MECHANICAL SEAL ! CAUTION


When the pump is intended to be equipped with a
A direction arrow is cast on the front of the
mechanical seal, it is Wilfley’s standard practice to
casing (See Figure 5). Make sure the motor
install the mechanical seal in the pump prior to
rotates in the same direction before coupling
shipment. Specific order requirements may
the motor to the pump. It is absolutely essential
specify that the seal be shipped separately, or
that the rotation of the motor be checked before
none be supplied. It is the pump installer’s
connecting the shaft coupling. Incorrect rotation of
responsibility to determine if a seal was installed.
the pump, for even a short time, can dislodge the
If a seal was supplied but not installed, the seal
impeller, which may cause serious damage to the
and installation instructions will be shipped with
pump. All Wilfley Model A9 pumps turn clockwise
the pump.
as viewed from the motor end, or conversely,
counterclockwise when viewed from the suction
end, as shown in Figure 5.

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As a final step in preparation for operation, it is


important to rotate the shaft by hand to be certain
that all rotating parts move freely and that there
are no foreign objects in the pump casing.

Starting
Before starting the pump, it is advisable to have
the pump casing and suction line filled with liquid.
It is normal to have the discharge valve
momentarily closed when the pump is started
since much less horsepower is required under
Figure 5 – Pump with Rotation Direction Arrow these conditions.

DO NOT OPERATE THE PUMP IN A DEAD-


5.2 PRE START-UP CHECKS HEAD (NO FLOW) CONDITION.
Prior to starting the pump, it is essential that the
following checks be made. 5.3 START-UP
CONSIDERATIONS
 Visually check all main and auxiliary piping
to ensure that all connections have been Ensuring Proper NPSHA
properly made.
Net Positive Suction Head – Available (NPSHA) is
 Check voltage, fuse, starter amperage the measure of the energy in a liquid above the
ratings and frequency on the motor vapor pressure. It is used to determine the
nameplate against the electrical supply likelihood that a fluid will vaporize in the pump. It
characteristics. is critical because a centrifugal pump is designed
to pump a liquid, not a vapor. Vaporization in a
 Visually inspect all electrical connections to pump will result in damage to the pump,
the motor and control circuit. deterioration of the Total Differential Head (TDH)
and possibly a complete stoppage of pumping.
 Check the rotation of the motor by
momentarily starting the motor with motor Net Positive Suction Head – Required (NPSHR) is
disconnected from the pump assembly. the decrease of fluid energy between the inlet of
Direction of rotation must be as shown by the pump and the point of lowest pressure in the
the arrow on the pump case and the pump. This decrease occurs because of friction
direction of rotation plate on the top of the losses and fluid accelerations in the inlet region of
frame. Starting or running pump backwards the pump and, particularly, accelerations as the
will cause damage. fluid enters the impeller vanes. The value for
NPSHR for the specific pump purchased is given
 Pump and motor are properly secured to in the pump data sheet and on the pump
the baseplate. performance curve. For a pump to operate
properly the NPSHA must be greater than the
 All fasteners tightened to the correct NPSHR. Good practice dictates that this margin
torques. should be at least 3 ft (1 m) or 20%, whichever is
greater.
 Coupling guard in place and not rubbing.

 Impeller clearance setting. ! CAUTION


 Bearing lubrication.
Ensuring that NPSHA is larger than NPSHR by
 Pump instrumentation is operational. the suggested margin will greatly enhance pump
performance and reliability. It will also reduce the
 Pump is primed. likelihood of cavitation, which can severely
damage the pump.

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Minimum Flow
Minimum continuous stable flow is the lowest flow
! WARNING
at which the pump can operate and still conform
to the bearing life, shaft deflection and bearing Do not operate the pump at or below Minimum
housing vibration limits of ANSI/ASME B73.1M- Thermal Flow, as this could cause an excessive
1991. Pumps may be operated at lower flows, but temperature rise. Contact a Wilfley Sales
it must be recognized that the pump may not Engineer for determination of Minimum Thermal
conform to one or more of these limits and the Flow.
operating life may be significantly reduced. For
example, vibration may exceed the limit set by the 5.4 STARTING THE PUMP AND
ASME H.I. 9.6 standard. The size of the pump,
the energy absorbed and the liquid pumped are
ADJUSTING FLOW
some of the considerations in determining the
1. Open the suction valve to full open position.
minimum flow. See the following table for general
It is very important to leave the suction
recommendations. Special conditions, such as
solids handling, may significantly raise these valve open while the pump is operating. Any
recommendations. throttling or adjusting of flow must be done
through the discharge valve. Partially
Table 3 – General Recommendations for closing the suction valve can create serious
Minimum Continuous Flow NPSH and pump performance problems.
% BEP
PUMP SIZE/
DESIGNATION
@ 3550 /
2950
@ 1750 /
1450 ! DANGER
RPM; RPM;
60/50 HZ 60/50 HZ
Never operate pump with both the suction
1.5x1-6 AA-6 15 10 and discharge valves closed. This could
3x1.5-6 AB-6 15 10 cause an explosion.
3x2-6 AC-6 15 10
1.5x1-8 AA-8 20 10 2. A standard centrifugal pump will not move
3x1.5-8 A50-8 20 10 liquid unless the pump is primed. A pump is
3x2-8 A60-8 20 10 said to be “primed” when the casing and the
4x3-8 A70-8 20 10 suction piping are completely filled with
2x1-10 A05-10 25 10 liquid. Open discharge valve a slight
3x1.5-10 A50-10 25 10 amount. This will allow any entrapped air to
3x2-10 A60-10 30 15 escape and will normally allow the pump to
4x3-10 A70-10 30 15 prime, if the suction source is above the
6x4-10 A80-10 30 15 pump. When a condition exists where the
3x1.5-13 A20-13 30 15 suction pressure may drop below the
3x2-13 A30-13 40 15 pump’s capability, it is advisable to add a
4x3-13 A40-13 40 40 low-pressure control device to shut the
6x4-13 A80-13 - 40 pump down when the pressure drops below
8x6-13 A90-13 - 40 a predetermined minimum.
6x4-15 A105-15 - 50
8x6-15 A110-15 - 50 3. All cooling, heating and flush lines must be
10x8-17 A120-15 - 50 started and regulated.

4. Start the driver (typically, the electric motor).


All Wilfley A9 pumps also have a “Minimum
Thermal Flow.” This is defined as the minimum
5. Slowly open the discharge valve until the
flow that will not cause an excessive temperature
desired flow is reached, keeping in mind the
rise. Minimum Thermal Flow is application
minimum flow restrictions listed above.
dependent.

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5.5 THERMAL SHOCK


! DANGER INSTRUCTIONS
It is important that the discharge valve be For thermal shock start-up instructions, please
opened within a short interval after starting contact the Wilfley factory in Denver.
the driver. Failure to do this could cause a
dangerous build up of heat and possibly an 5.6 OPERATION IN SUB-
explosion.
FREEZING CONDITIONS
6. Reduced Capacity
Avoid running a centrifugal pump at When using the pump in sub-freezing conditions
drastically reduced capacities or with the where the pump is periodically idle, the pump
discharge valve closed for extended periods should be properly drained or protected with
of time. This can cause severe temperature thermal insulating devices which will keep the
rise and the liquid in the pump may reach its liquid in the pump from freezing. High-chrome iron
boiling point. If this occurs at a minimum, pumps are not recommended for applications
the seal may be damaged, as it will be below 0°F (-18°C).
exposed to vapor, will have no lubrication
and may score or seize to the stationary 5.7 SHUTDOWN
parts. It is also possible that it can create an CONSIDERATIONS
explosive condition. If the suction valve is
also closed, there is an even greater risk of When the pump is being shut down, the
catastrophic failure such as an explosion. procedure should be the reverse of the start-up
procedure. First, slowly close the discharge valve,
Thermostats may be used to safeguard shut down the driver and then close the suction
against over heating by shutting down the valve. Remember, closing the suction valve while
pump at a predetermined temperature
the pump is running is a safety hazard and could
seriously damage the pump and other equipment.
Safeguards should also be taken against
possible operation with a closed discharge
valve, such as installing a bypass back to 6.0 PREVENTIVE MAINTENANCE
the suction source. The size of the bypass
line and the required bypass flow rate is a 6.1 GENERAL SERVICING
function of the input horsepower and the
allowable temperature rise. Your Wilfley Model A9 pump is designed to
provide long and trouble-free service with a
7. Reduced Head minimum of maintenance. It is recommended that
Note that when discharge head drops, the the pump be inspected at regular intervals. It is
pump’s flow rate usually increases rapidly. also suggested that a service record be kept for
Check motor for temperature rise as this the pump.
may cause overload. If overloading occurs,
throttle the discharge. Motor
8. Surging Condition
Refer to the motor manufacturer’s manual for
A rapidly closing discharge valve can cause recommended service instructions. It is
a damaging pressure surge. A dampening recommended that the motor be well ventilated
arrangement should be provided in the when in operation.
piping.

6.2 PERIODIC SERVICING


The following table contains recommended
service checks that should be performed on a
periodic basis.

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Table 4 – Recommended Service Checks Need for Maintenance Records


After Every Every
First Week 6 A procedure for keeping accurate maintenance
Start- Months records is a critical part of any program to improve
Up pump reliability. There are many variables that
Flow, Pressure, can contribute to pump failures. Analyzing these
X X
Temperature (a) variables through pump maintenance records can
Visual (b) X X only solve often-long term and repetitive
problems.
Noise / Vibration X X
Need for Cleanliness
Oil Level X X
One of the major causes of pump failure is the
Grease Bearings X X presence of contaminants in the bearing housing.
This contamination can be in the form of moisture,
dust, dirt and other solid particles, such as metal
a. Flow, Pressure, Temperature: All flow, chips. Contamination can also be harmful to the
pressure and temperature gauges should seal (especially the seal faces) as well as other
be monitored to ensure that the pump is parts of the pumps. For example, dirt in the
operating within specified limits. If the frame impeller threads could cause the impeller to not
temperatures are monitored, this be seated properly against the shaft. This, in turn,
temperature generally should not exceed could cause a series of other problems. For these
160°F (71.1°C). reasons, it is very important that proper
cleanliness be maintained.
b. Visual: Periodic visual inspection should be
made of the pump and its installation.
6.3 MAINTENANCE
This inspection should include the following: TROUBLESHOOTING
1. All mounting supports should be secure. The following is a guide to troubleshooting
problems with Wilfley pumps. Common problems
2. All external nuts, bolts and fittings should be are analyzed and solutions are offered.
tight. Obviously, it is impossible to cover every possible
scenario. If a problem exists that is not covered by
3. All suction and discharge piping should be one of the examples, then contact a Wilfley Sales
secure. Engineer or Wilfley Distributor/Representative for
assistance.
4. All surfaces and joints should show no signs
of leakage. See next page.

! WARNING
To re-grease bearings under the coupling guard,
stop pump, lock the motor, remove the coupling
guard, then re-grease the bearings.

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Table 5 – Maintenance Troubleshooting


PROBLEM POSSIBLE CAUSE RECOMMENDED REMEDY
Recalculate NPSH available. It must be greater than the
NPSH required by pump at desired flow. If not, redesign
Insufficient NPSH. suction piping, holding the number of elbows and number of
planes to a minimum to avoid adverse flow rotation as it
approaches the impeller.
System head greater than Reduce system head by increasing the pipe size and/or
anticipated. reducing the number of fittings.
Check suction line gaskets and threads for tightness.
Entrained air. Air leak
If vortex formation is observed in the suction tank, install
from atmosphere on
vortex breaker.
suction side.
Check for minimum submergence.
Entrained gas from
Process-generated gases may require larger pumps.
process.
Pump not Speed too low. Check motor speed against design speed.
reaching design After confirming wrong rotation, reverse any two of three
flow rate. Direction of rotation leads on a three-phase motor.
Problem #1 wrong. The pump should be disassembled and inspected before it is
restarted.
Replace with proper diameter impeller.
Impeller too small. NOTE: Increasing impeller diameter may require use of a
larger motor.
Impeller clearance too
Reset impeller clearance.
large.
Plugged impeller, suction
Reduce length of fiber when possible.
line or casing, which may
Reduce solids in the process fluid when possible.
be due to a product or
Consider larger pump.
large solids.
Wet-end parts (casing
cover, impeller) worn, Replace part or parts.
corroded or missing.
Pump not
reaching design Refer to possible causes
Refer to remedies listed for Problem #1 & #3.
head (TDH). under Problem #1.
Problem #2
Repeat priming operation and recheck instructions. If pump
Not properly primed. has run dry, disassemble and inspect the pump before
operation.
After confirming wrong rotation, reverse any two of three
Direction of rotation leads on a three-phase motor.
wrong. The pump should be disassembled and inspected before
operation.
No discharge or Check suction line gaskets and threads for tightness.
Entrained air. Air leak
flow. If vortex formation is observed in suction tank, install vortex
from atmosphere on
Problem #3 breaker.
suction side.
Check for minimum submergence.
Plugged impeller and/or
Reduce length of fiber when possible.
suction line casing, which
Reduce solids in the process fluid when possible.
may be due to a fibrous
Consider larger pump.
product or large solids.
Damaged pump shaft
Replace damaged parts.
and/or impeller.

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PROBLEM POSSIBLE CAUSE RECOMMENDED REMEDY


Recalculate NPSH available. It must be greater than the
NPSH required by pump at desired flow. If not, redesign
Pump operates Insufficient NPSH. suction piping, holding the number of elbows and number of
for short period, planes to a minimum to avoid adverse flow rotation as it
then loses approaches the impeller.
prime. Check suction line gaskets and threads for tightness.
Entrained air. Air leak
Problem #4 If vortex formation is observed in the suction tank, install
from atmosphere on
vortex breaker.
suction side.
Check for minimum submergence.
Recalculate NPSH available. It must be greater than the
NPSH required by pump at desired flow. If not, redesign
Cavitation – insufficient
suction piping, holding the number of elbows and number of
NPSH available.
planes to a minimum to avoid adverse flow rotation as it
Excessive noise
approaches the impeller.
from wet end.
Abnormal fluid rotation Redesign suction piping, holding the number of elbows and
Problem # 5
due to complex suction number of planes to a minimum to avoid adverse fluid
piping. complex suction piping rotation as it approaches the impeller.
Check and reset impeller clearance.
Impeller rubbing.
Check outboard bearing assembly for axial endplay.
Replace bearings.
Work with clean tools in clean surroundings.
Remove all outside dirt from housing before exposing
Bearing contamination
bearings.
appearing on the
Handle with clean, dry hands.
raceways as scoring,
Treat a used bearing as carefully as a new one.
pitting, scratching or
Use clean solvent and flushing oil.
rusting caused by
Protect disassembled bearing from dirt and moisture.
adverse environment and
Keep bearings wrapped in paper or clean cloth while
entrance of abrasive
not in use.
contaminants from
Clean inside of housing before replacing bearings.
atmosphere.
Check oil seals and replace as required.
Check all plugs and tapped openings to make sure that they
are tight.
Brinelling of bearing
identified by indentation Replace bearings.
Excessive noise on the ball races, usually When mounting the bearing on the drive shaft use a proper
from power end. caused by incorrectly size ring and apply the pressure against the inner ring only.
Problem #6 applied forces in Be sure, when mounting a bearing, to apply the mounting
assembling the bearing or pressure slowly and evenly.
by shock loading such as
hitting the bearing or drive
shaft with a hammer.

Replace bearings.
False brinelling of bearing
Where bearings are oil lubricated and employed in units that
identified by either axial
may be out of service for extended periods, the drive shaft
or circumferential
should be turned over periodically to relubricate all bearing
indentations usually
surfaces at intervals of one to three months.
caused by vibration of the
Correct the source of vibration.
balls between the races in
a stationary bearing.

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PROBLEM POSSIBLE CAUSE RECOMMENDED REMEDY


Thrust overload on
bearing identified by
(Cont.) flaking ball path on one
Excessive noise side of the outer race or,
from power end. in the case of maximum
Problem #6 capacity bearings, may Replace bearings.
appear as a spalling of Follow correct mounting procedures for bearings.
the races in the vicinity of
the loading slot. These
thrust failures are caused
by improper mounting of
the bearing or excessive
thrust loads.
Misalignment identified by
fracture of ball retainer or
a wide ball path on the
inner race and a narrower
cocked ball path on the Replace bearings.
outer race. Misalignment Handle parts carefully and follow recommended mounting
is caused by poor procedures.
mounting practices or Check all parts for proper fit and alignment.
defective drive shaft. For
example, bearing not
square with the centerline
or possibly a bent shaft
due to improper handling.
Bearing damaged by
electric arcing identified Replace bearings.
as electro-etching of both Where current shunting through the bearing cannot be
inner and outer ring or as corrected, a shunt in the form of a slip-ring assembly should
pitting or cratering. be incorporated.
Electrical arcing is caused Check all wiring, insulation and rotor windings to be sure that
by a static electrical they are sound and all connections are properly made.
charge emanating from Where pumps are belt driven, consider the elimination of
belt drives, electrical static charges by proper grounding or consider belt material
leakage or short- that is less generative.
circuiting.
Bearing damage due to
improper lubrication,
Replace bearings.
identified by one or more
Be sure the lubricant is clean.
of the following:
Be sure proper amount of lubricant is used.
Abnormal bearing
In the case of greased, lubricated bearings, be sure that
temperature rise
there is space adjacent to the bearing into which it can rid
A stiff, cracked grease
itself of excessive lubricant; otherwise, the bearing may
appearance.
overheat and fail prematurely.
A brown or bluish
Be sure the proper grade of lubricant is used.
discoloration of the
bearing races.

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7.0 A9 WITH DRYLOCK® II SEAL DISASSEMBLY & REASSEMBLY


The following sections of this manual give instructions on how to perform a complete maintenance overhaul.
However, it is also important to periodically repeat the “Pre start-up checks” listed on page 12. These checks
will help extend pump life as well as the length of time between major overhauls.

Refer to Figures 6 through 19 for item number references used throughout this section.

Note: The pictures in the following section represent typical parts to clarify assembly. Details of the parts may
differ slightly from parts supplied with the pump.

17 9 2J 2B 2H 2A 2M 3J 3G*

3C

16
3F*

3E*

3B

3P
5R*

3C

3D
14

3A

11

12* 8 3E* 2E 2F* 3M* 2N 2K 2D 2G 3K 3H*

ITEM NO. QTY. DESCRIPTION ITEM NO. QTY. DESCRIPTION


2A 1 BEARING FRAME 3F* 1 LOCKNUT
2B 1 FRAME BRACKET 3G* 1 OUTBOARD BEARING
2D 1 FRAME FOOT 3H* 1 O-RING, BEARING CARRIER
2E 1 INBOARD BEARING COVER 3J 1 BEARING CARRIER COVER
2F* 1 INBOARD BEARING COVER GASKET 3K 4 CAP SCREW
2G 3 CAP SCREW 3M* 1 INBOARD BEARING
2H 3 CAP SCREW 3P 1 KEY
2J 5 CAP SCREW 5R* 1 O-RING, IMPELLER
2K 2 OIL SIGHT GLASS 8 1 DRYLOCK® II SEAL ASSEMBLY
2M 1 OIL FILL PLUG 9 81 CAP SCREW
2N 1 OIL DRAIN MAGNETIC PLUG 11 1 CASE PLATE
3A 1 BEARING CARRIER 12* 1 CASE GASKET
3B 1 SHAFT 14 1 EXPELLER
3C 6 CAP SCREW 16 1 IMPELLER
3D 3 JAM NUT 17 1 CASING
3E* 2 OIL SEAL

Notes:

* Recommended spare parts


1
Frame 3 has qty. 12 cap screws
®
Figure 6 – A9 Pump with DryLock II Seal

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7.1 DISASSEMBLY 12. Mount a shaft key and a shaft wrench to the
end of the shaft (3B). With the wrench
1. Before performing any maintenance, handle pointing to the left when viewed from
disconnect the driver from its power supply the impeller end, grasp the impeller firmly
and lock it off line. with both hands (wear heavy gloves) and
then rotate it until the wrench handle is at
the 11 o’clock position; next, spin the
! DANGER impeller quickly in a counterclockwise
direction so that the wrench end makes a
sudden impact with a hard surface. After
Lock out power to driver to prevent personal several sharp raps, the impeller should be
injury. loose. The shaft wrench can be fabricated
locally, per the shaft wrench drawing (see p.
2. Close the discharge and suction valves and 42).
drain all liquid from the pump.
13. Unscrew the impeller and remove it from the
3. Close all valves on auxiliary equipment and shaft.
piping, then disconnect all piping.

4. Decontaminate the pump as necessary. ! DANGER


! DANGER Do not apply heat to the impeller. An
explosion could occur.

If Wilfley pumps contain dangerous 14. Remove the case plate (11) and the
chemicals, it is important to follow plant expeller (14). Next, remove the large o-ring
safety guidelines to avoid personal injury or (10) found between the plate and the seal
death. housing (7A), then remove the complete
seal housing assembly.
5. Remove the coupling guard.
15. Loosen the three jam nuts (3D) on the three
6. Remove the spacer from the coupling. jacking bolts (3C) on the bearing carrier
(3A), then remove the three bolts. Loosen
7. Disconnect any seal drain piping. and remove the three retaining bolts (3A).

8. Remove the fasteners holding the bearing 16. Remove the bearing carrier assembly with
frame (2A) and case (1) to the baseplate. the shaft and bearings from the bearing
Remove pump and relocate to a frame and discard the o-ring (3H).
workstation.
17. Remove the oil seals (3E) from the frame
and bearing carrier and discard them.
! CAUTION Further disassembly is not required unless
the bearings are to be replaced.
It is important to follow plant safety
guidelines when lifting pump components. Replacing the Bearings

9. Remove drain plug (2N) and drain oil from 1. Remove the bearing carrier cover fasteners
the bearing frame (2A). Replace drain plug (3K) from the bearing carrier (3A).
when done.
2. Remove the bearing carrier cover (3J).
10. Remove the coupling hub from the pump
shaft. 3. The bearing locknut (3F) may now be
removed from the shaft.
11. Remove the fasteners (9) holding the
casing to the bearing frame, remove casing 4. An arbor or hydraulic press may be used to
(17) and discard the casing gasket (12). remove the bearings from the shaft. It is
extremely important to apply even pressure

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to the inner bearing race only. Never apply


pressure to the outer race as this exerts
excess load on the balls and causes
! WARNING
damage. We recommend that all bearings
be replaced after disassembly. It is important that only nonflammable,
noncontaminated cleaning fluids are used. These
fluids must comply with plant safety and
! CAUTION environmental guidelines.

7.3 CRITICAL MEASUREMENT


Applying pressure to the outer race could
permanently damage the bearings. AND TOLERANCES
To maximize reliability of pumps, it is important
7.2 CLEANING/INSPECTION that certain parameters and dimensions are
measured and maintained within specified
All parts should now be thoroughly cleaned and tolerances. Any parts that do not conform to the
inspected. New bearings, o-rings, gaskets and oil specifications should be replaced with new Wilfley
seals should be used. Any parts that show wear parts.
or corrosion should be replaced with OEM Wilfley
parts.
Shaft
Casing
The seal-mounting surface includes the shaft
and/or shaft sleeve outside diameter within the
 Thoroughly clean gasket surfaces and
seal housing and extending beyond to
alignment fits to remove rust and debris.
accommodate outside seals. To provide for the
possible use of a mechanical seal, the tolerance
 Inspect for any unusual erosive wear in
of that diameter shall not exceed nominal minus
volute.
0.002 in. (0.05 mm).
Impeller/Expeller
Shaft runout shall be limited as follows:
 Inspect leading and trailing edges of vanes
1. Shaft rotated on centers: 0.001 in.
for pitting, erosion or corrosion damage.
(0.025mm) full indicator movement reading
at any point.
Frame
2. Outside diameter of shaft or removable
 Inspect frame, bracket and frame foot for sleeve when installed on pump: 0.002 in.
cracks. (0.05mm) full indicator movement at the
gland end of the seal housing.
 Inspect for corrosion or pitting if frame has
been exposed to pumpage. See next page.
 Inspect shafts and sleeves for wear.

 Inspect frame bearing bores for roundness.

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7.4 ASSEMBLY
Assembly videos are available online at www.wilfley.com/support/instruction-videos.html or you can scan the
QR codes below with your smartphone:

® ®
DryLock II A1 Seal Assembly DryLock II A2 Seal Assembly

Full thread length engagement is required for all fasteners.


Lightly lubricate all seal o-rings to prevent damage.

2M

2A

2H 2E 2F 2K
3

2B

2K

2J
5

2G
3
2N 2D

Figure 7 – A9 Frame Assembly

1. Attach foot frame (2D) to frame (2A) using fasteners (2G). Install pipe plugs (2M, 2N) and oil gauges
(2K) onto frame (2A). Install cap screws (2H), inboard bearing cover (2E) and inboard bearing gasket
(2F) onto frame. Attach bracket (2B) with cap screws (2J).

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Bearing Installation
Mounting of bearings on shafts must be done in a clean environment. Bearing and power-end life can be
drastically reduced if even very small foreign particles work their way into the bearings.
Bearings should not be removed from their protective packaging until immediately before assembly to limit
exposure to possible contamination. After the packaging is removed, bearings should only come into contact
with clean hands, fixtures, tools and work surfaces.

Note that the term “inboard bearing” refers to the bearing nearest to the casing. “Outboard bearing” refers to
the bearing nearest to the motor.

Both bearings have a slight and preferred interference fit that requires that they be pressed on the shaft with
an arbor or hydraulic press. Even force should be applied to the inner race only. Never press on the outer
race, as the force will damage the balls and races. An alternate and preferred method of installing bearings is
to heat the bearings to 200°F (93°C) in an oven or with an induction heater. Then place them quickly in
position on the shaft.

! CAUTION
Never heat the bearings above 230°F (110°C). To do so will likely cause damage to bearing and seal.

3M

3B

3J

3G

3F

Figure 8 – A9 Shaft Assembly Step 1

2. Install the outboard bearing retaining cover (3J), outboard angular bearing (3G) and locknut (3F) onto
the shaft (3B). *Note: Use back-to-back bearing orientation when there are two angular contact
bearings.* Then install inboard bearing (3M) onto shaft. It is recommended that a bearing heater be
used when installing bearings to avoid damage to the races. Be sure the bearing seats against the
shoulder of the shaft. If the pump is grease lubricated, hand pack the bearings with the appropriate
grease (reference Section 9.0) after the bearings are seated on the shaft.

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3K
COMPLETED
ASSEMBLY
FROM STEP 1

3H

3A

3E

Figure 9 – A9 Shaft Assembly Step 2

3. Install the outboard oil seal (3E) into the bearing carrier (3A). Please be sure that the notch in the seal
faces down for drainage. Install o-ring (3H) onto bearing carrier. Slide bearing carrier over rear bearing
(3G) and attach rear bearing retainer cover (3J) with cap screws (3K).

3E
COMPLETED
FRAME
ASSEMBLY
COMPLETED
ASSEMBLY
FROM STEP 2

3C
3 3P
3C
3
3D
3

Figure 10 – A9 Shaft Assembly Step 3

4. Install the inboard oil seal (3E) into the frame. Install the bearing carrier o-ring (3H) into the groove of
the bearing carrier. To avoid damage, lubricate the o-ring with light oil and slide the assembly into the
frame. The word “top” on the carrier must face up. Attach the bearing carrier with three retaining bolts
(3C), jacking bolts (3C) and jam nuts (3D). Clearance values and adjustment procedure follows the
®
DryLock II Seal assembly steps. Attach square key (3P) onto shaft.

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ITEM
QTY. DESCRIPTION
NO.
4A 1 BALL HOUSING
4B 1 BALL RETAINER
4C 3-18 BALLS
4D 1 RETAINING RING
4E 1 SPRING PIN
4F 1 KEY
5A 1 SHAFT SLEEVE
5B 1 RETAINING RING
5C* 1 O-RING, SHAFT SLEEVE
5D 4 DRIVE SCREW
5E 4 DRIVE SCREW SLEEVE
5F 1 ACTUATOR PLATE
5G 1 SEAL SLEEVE
5J 1 WAVE SPRING
5K* 1 SLIDE RING
5M 1 LOCKNUT
5N 1 ROTARY SEAL RING
5P* 1 O-RING, ROTARY SEAL
5Q* 1 O-RING, SEAL SLEEVE
5R* 2 O-RING, EXPELLER
7A 1 SEAL HOUSING
7B 1 SEAL CARTRIDGE
7C 1 DISASTER BUSHING
7D* 1 STATIONARY SEAL RING
7E* 1 O-RING, STAT RING
7F* 1 O-RING, CARTRIDGE
7G* 1 VARILIP
7J** 1 QUICK RELEASE PIN
7S** 1 POSI-LOCK PIN
7T** 1 POSI-LOCK BOLT
10* 1 O-RING, SEAL HOUSING
11 1 CASE PLATE
14 1 EXPELLER
29 1 DRAIN SPOUT

* Recommended spare parts


** Seal will be fitted with Quick Release
Pin OR Posi-Lock Pin

Figure 11 – DryLock® II Style A1 For A9 Pump

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ITEM
QTY. DESCRIPTION
NO.
4A 1 BALL HOUSING
4B 1 BALL RETAINER
4C 3-18 BALLS
4D 1 RETAINING RING
4E 1 SPRING PIN
4F 1 KEY
5A 1 SHAFT SLEEVE
5B 1 RETAINING RING
5C* 1 O-RING, SHAFT SLEEVE
5D 4 DRIVE SCREW
5E 4 DRIVE SCREW SLEEVE
5F 1 ACTUATOR PLATE
5G 1 SEAL SLEEVE
5J 1 WAVE SPRING
5K* 1 SLIDE RING
5M 1 LOCKNUT
5N 1 ROTARY SEAL RING
5P* 1 O-RING, ROTARY SEAL
5Q* 1 O-RING, SEAL SLEEVE
5R* 2 O-RING, EXPELLER
7A 1 SEAL HOUSING
7B 1 SEAL CARTRIDGE
7C 1 DISASTER BUSHING
7D* 1 STATIONARY SEAL RING
7E* 1 O-RING, STAT RING
7F* 1 O-RING, CARTRIDGE
7G* 1 WIPER SEAL
7J** 1 QUICK RELEASE PIN
7S** 1 POSI-LOCK PIN
7T** 1 POSI-LOCK BOLT
10* 1 O-RING, SEAL HOUSING
11 1 CASE PLATE
14 1 EXPELLER
29 1 DRAIN SPOUT

* Recommended spare parts


** Seal will be fitted with Quick Release
Pin OR Posi-Lock Pin

Figure 12 – DryLock® II Style A2 For A9 Pump

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4A
4F

4C

4B

4D

4E
®
Figure 13 – A9 DryLock II Ball Assembly

FRAME 950 1150 1450 1750 2950 3550


NO. RPM RPM RPM RPM RPM RPM
1 18 12 9 6 3 3
2 18 12 9 6 3 3
3 18 12 9 6 3 3
4 18 12 9 6 - -
®
Figure 13A – Number of DryLock II Actuator Balls per Pump RPM

5. Insert spring pin (4E) into ball housing (4A). Place balls (4C) into the ball retainer (4B) slots. For
smooth operation, the balls must be symmetrically placed. Please note the small hole on the face of
the ball retainer. This hole will fit over the spring pin. Be sure the spring pin fits into the hole of the ball
retainer. Then align ball retainer into ball housing (4A). Lock into place with retaining ring (4D) to the
hub of the ball housing. Lastly, insert key (4F) onto ball housing.

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5G
5K

5P

5N

5M

APPLY TEFLON®
LUBRICATION
TO THREADS

®
Figure 14 – A9 Rotating DryLock II Assembly Step 1

6. Slide o-ring (5P) over seal sleeve (5G). Make sure it is in the groove after the threads. Slide rotary seal
ring (5N) over o-ring then tighten with lock nut (5M). Insert slide ring (5K) into seal sleeve.

**NOTE: Lock nut (5M) has left hand threads**

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5Q

5A

5J
5C

COMPLETED
ASSEMBLY FROM
PREVIOUS STEP
®
Figure 15 – A9 Rotating DryLock II Assembly, Step 2

7. Slide wave spring (5J) over shaft sleeve (5A). Place o-ring (5Q) into groove in the shaft sleeve.
Lubricate o-ring and then carefully insert into the completed assembly from the previous step. Take
care when pushing the shaft sleeve past the slide ring (5K). Try to center the keyway directly between
the tapped holes in the assembly created in Step 1. Then install o-ring (5C) into the groove in the shaft
sleeve (5A).

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7B

7F

7C

7E
7D

®
Figure 16 – A9 Stationary DryLock II Assembly Step 1

8. Press disaster bushing (7C) into cartridge seal (7B). Insert o-ring (7E) and lubricate prior to inserting
the stationary seal ring (7D) into cartridge seal. When installing the stationary seal ring, make sure that
the tabs in the part align with the slots in the seal cartridge (7B). Insert o-ring (7F) into the groove in the
seal cartridge. Carefully inspect the stationary seal ring (7C) to insure that it has seated fully before
installation. The inside surface of the seal ring is the stationary seal face and must be free of scratches
or nicks.

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7A

7G

®
Figure 17 – A9 Stationary DryLock II Assembly Step 2 – Varilip Configuration

9. VARILIP CONFIGURATION: Press the Varilip seal (7G) into the seal housing (7A) with the lip facing
toward the suction of the pump.

7A

7G

®
Figure 18 – A9 Stationary DryLock II Assembly Step 2 – Wiper Seal Configuration

WIPER SEAL CONFIGURATION: Insert the Wiper Seal (7G) into the seal housing (7A). Bend the seal
into a crescent moon shape in order to fit it into the angled groove. Make sure that the seal is
completely inserted in the groove before continuing.

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COMPLETED STATIONARY
ASSEMBLY STEP 2

COMPLETED STATIONARY
ASSEMBLY STEP 1
5F
5E
5D

5B

4F
COMPLETED ROTATING
ASSEMBLY STEP 2

COMPLETED
BALL HOUSING
ASSEMBLY
®
Figure 19 – A9 Complete DryLock II Assembly

10. Insert Rotating Assembly Step 2 into Stationary Assembly Step 2. Apply Teflon paste generously to
threads of Stationary Assembly Step 1 and lubricate o-ring before threading into Stationary Assembly
Step 2. **Do not overtighten – Leave 1 visible thread.** Tighten actuator plate (5F) with flat cap screws
(5D) and drive screw sleeves (5E). It is recommended that “blue Loctite” be applied to the cap screws
(5D) to ensure they do not unscrew during operation. Recheck that the keyway in the shaft sleeve is
directly between the flat cap screws. Insert the key (4F) into the keyway in the shaft sleeve. Slide the
Ball Housing Assembly over the Rotating Assembly created in Step 1 and lock it with retaining ring
(5B). Adjustment may be needed to make sure that the cap screws, key and ball housing assembly fit
correctly.
®
*Note: The complete DryLock II Assembly (8) can be purchased fully assembled and ready to
install.*

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5R
14
10
11
5R
12
16

17

COMPLETE
DRYLOCK II™
29
SEAL ASSEMBLY

Figure 20 – A9 Complete Pump Assembly


®
11. Lubricate o-ring (5C). Install the DryLock II Assembly to the power end. The seal flush should be at
the 12 o’clock position and the drain at the 6 o’clock position. A Drain nipple (29) may have been
®
supplied with the DryLock II seal. The nipple can be screwed in to the drain port after pump assembly,
use Teflon tape on the threads.

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DIM A.
FRAME 1 30°
FRAME 2 50°
FRAME 3 15°
FRAME 4 20°
Figure 21 – Flush Configuration

12. Seat the seal housing o-ring (10) and the shaft sleeve o-ring (5R) in their grooves.

13. Place the expeller o-ring (15) into the groove on the expeller (14). Place the expeller onto the shaft.
®
14. Place the case plate (11) onto the DryLock II Seal Assembly.

15. Screw the impeller (16) onto the shaft. Be sure the impeller is securely tightened; use of a shaft wrench
is recommended to assist in the tightening process.

16. Install case gasket (12) onto the case plate (11). Use a grease type substance to secure the gasket if it
does not stay in place.

17. Secure the casing (17) to the frame with the supplied bolts (9).

18. Set the impeller clearances using one of the following methods and set the clearances according to
table 6 below. Wilfley recommends that the dial indicator method be used to set the clearances.
® ®
19. Set the DryLock II seal clearances using the DryLock II Seal Clearance Adjustment Procedures
below.

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Impeller Clearance the casing (17). Turn the shaft to ensure


contact is made.
Cold temperature clearance (in.) for various
service temperatures 4. Set indicator to zero and back the retaining
bolts out one turn.
5. Tighten the jacking bolts so they evenly
Standard A9 Pump (about one flat at a time) move the bearing
carrier away from the frame until the
See table below for clearances between casing indicator shows the clearance for your
and impeller. pump (see chart).
Table 6 – Casing and Impeller Clearances 6. Evenly tighten all jack and retaining bolts so
Max. that they are equally tight. Recheck the dial
Frame Frame Frame Frame
Service indicator to ensure the proper clearance has
1 2 3 4
Temp. been maintained.
200F
0.010 0.011 0.013 0.017 7. Check shaft to be sure it turns freely.
(93C)
250F
0.012 0.013 0.015 0.019 Feeler Gauge Procedures
(121C)
300F
0.014 0.015 0.017 0.021
(149C)
400F
0.017 0.018 0.020 0.024
(204C)
+/- 0.001” Tolerance

Dial Indicator Procedures

Figure 23 – Feeler Gauge Method

1. Loosen jam nuts (3D) on jacking bolts (3C)


and back out approximately two turns.

2. Tighten each retaining bolt (3C) evenly,


drawing bearing carrier (3A) towards the
frame (2A) until the impeller (16) contacts
Figure 22 – Dial Indicator Method (Preferred the casing (17). Turn the shaft (3B) to
Method) ensure contact is made.

1. Set indicator so that button contacts the end 3. With a feeler gauge, set the gap between
of the shaft (3B). the three sets of bolts and bearing carrier
that corresponds to the proper clearance for
2. Loosen jam nuts (3D) on jacking bolts (3C) your pump (see Table 6).
and back jack bolts out two turns.
4. Evenly back out bearing carrier using the
3. Tighten each retaining bolt (3C) evenly three jacking bolts until it contacts the
drawing the bearing carrier (3A) towards the retaining bolts. Evenly tighten jam nuts.
frame (2A) until the impeller (16) contacts
5. Check shaft to be sure it turns freely.

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DryLock® II Seal Clearance Adjustment Procedures (Posi-Lock Type)


1. Loosen bolt (7T) so Posi-Lock pin (7S) slides freely, pull pin out of
cartridge slot allowing the cartridge to rotate freely.

2. If not already done, using a 1/2” (Frame 4: 5/8”) open ended wrench,
loosen the seal cartridge (7B) until approximately 1 full thread is visible.

3. Set the pump impeller clearances according to the procedures above.

4. Using the open ended wrench, tighten the seal cartridge (7B) until you
feel it bottom out solidly.

5. Frame 1 & 2: Using the open ended wrench, loosen the cartridge a total
of 4 tabs. If you are halfway between tabs, loosen the cartridge the half
tab plus 4 additional tabs.
Frame 3 & 4: Using the open ended wrench, loosen the cartridge a total
1
of 5 tabs. If you are halfway between tabs, loosen the cartridge the half
tab plus 5 additional tabs. 2
4 3

6. Insert the Posi-Lock pin (7S) between the cartridge to prevent rotation of
the cartridge during pump operation.

7. Tighten Posi-lock locking bolt (7T) so that the pin can no longer slide.

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DryLock® II Seal Clearance Adjustment Procedures (Quick Release Pin Type)


1. Remove the quick release pin (7J) to allow the cartridge to rotate freely.

2. If not already done, using a 1/2” (Frame 4: 5/8”) open ended wrench,
loosen the seal cartridge (7B) until approximately 1 full thread is visible.

3. Set the pump impeller clearances according to the procedures above.

4. Using the open ended wrench, tighten the seal cartridge (7B) until you
feel it bottom out solidly.

5. Frame 1 & 2: Using the open ended wrench, loosen the cartridge a total
of 4 tabs. If you are halfway between tabs, loosen the cartridge the half
tab plus 4 additional tabs.
Frame 3 & 4: Using the open ended wrench, loosen the cartridge a total
of 5 tabs. If you are halfway between tabs, loosen the cartridge the half
tab plus 5 additional tabs.

6. Insert the quick release pin (7J) to prevent rotation of the cartridge during
pump operation.

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7.5 ASSEMBLY Reinstallation


TROUBLESHOOTING 1. Reinstall the pump to the base.
See table below for possible assembly issues.

Table 7 – Assembly Troubleshooting ! CAUTION


SYMPTOM CAUSE
Excessive Bearing internal clearance too The pump should be reinstalled as
shaft endplay. great. Replace bearings with described in the installation section by
correct type. Snap ring loose in following the field installation and alignment
bearing housing groove. Reseat. procedures.
Excessive Sleeve worn. Replace.
shaft/sleeve Shaft bent. Replace. 2. Install the coupling following the
runout. manufacturer’s installation instructions.
Excessive Shaft bent. Replace. Bearing
bearing frame frame flange distorted. Replace. 3. Install the coupling guard, ensuring that the
flange runout. guard is not in contact with the shaft and
Excessive Corrosion. Replace. Adapter to coupling.
frame adapter frame gasket not seated
runout. properly. Reseat. Please refer to the pre start-up instructions.
Excessive seal Seal housing not properly Follow all safety precautions and ensure that all
housing box seated in frame. Corrosion or safety guards are in place.
cover runout. wear. Replace.
Excessive Bent vane(s). Replace impeller. See next page.
impeller vane
tip runout.

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7.6 TROUBLESHOOTING PUMP LEAKS

On pump coast down:

{
Seal is not closing fast enough

On pump shutdown:
Stationary (7D) or rotary seal
ring (5N) is damaged

O-ring (10) failed

Case gasket (12) failed

®
Figure 24 – A9 DryLock II Seal Leakage Paths

Use Figure 24 and refer to the following page for troubleshooting tips.

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Pump Leaks

Whenever leakage is encountered and before removing your Wilfley pump, determine when the leakage is
occurring: while running, or while not running. During these inspections you should try to determine the exact
origin of the leak. Special attention should be given to the shaft sleeve. Once you have determined when the
pump is leaking, refer to the guide below.

Pump Leaks While Running.

Test Test Results Indicates


Visually determine the exact Leakage from the seal area Pump suction pressure exceeds expeller
leakage point. at shaft sleeve. capacity.
Excessive expellers wear, corrosion, clearance
or plating between vanes.
Pump running too slowly.
Leakage comes from case or Damaged seal surface, gasket failure or loose
gasket area. bolts.

Pump Leaks While NOT Running

Test Test Results Indicates


Verify that leakage originates Leakage comes from case or Damaged sealing surface gasket failure or
from the seal area. gasket area. loose bolts.
Verify that leakage originates Leakage is observed on seal Seal or actuator problem.
from the seal area. or shaft sleeve.

Lube Seal Vapor Leak

Test Test Results Indicates


Check for vapors coming Vapors detected. Lubricator is out of lubricant.
from the seal area.
Lubricator has failed.

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8.0 LUBRICATION
Bearing Lubrication
Oil Lubrication
Fill the frame until the oil level is approximately in the middle of the sight glass.

Table 8 – Acceptable Oils


Chevron GTS Oil 68
Exxon Teresstic EP 68
Gulf Gulf Harmony 68
Mobil Mobil DTE26 300 SSU 100°F (38°C)
Phillips Mangus Oil Grade 315
Phillips MM motor Oil SAE 20-20W

Table 9 – Lubricating Oil Requirements


Process Liquid Temp. Process Liquid Temp.
< 300°F > 300°F
ISO Grade VG 68 VG 100
Approx. SSU at 100°F (38°C) 300 470
DIN 51517 C68 C100
Kinem. viscosity at 68 100
2
105°F (40.6°C) in mm /sec

Table 10 – Approximate Oil Volumes


Oil Volume
Frame 1 12 oz. [350 ml]
Frame 2 51 oz. [1500 ml]
Frame 3 51 oz. [1500 ml]
Frame 4 93 oz. [2750 ml]

Wilfley recommends that the oil be changed according to the customer’s preventive maintenance program.
Every service can be different, which varies the length of time between oil changes. If a maintenance
program is already in place, follow that. If no program is in place, Wilfley recommends changing the pump oil
once every 3 months.

Grease Lubrication
Bearings should be hand packed during assembly and reassembly.
Further lubrication should be done per periodic servicing. Reference Section 6.2.
Recommended grease: Grease SRI #2

9.0 ORDERING PARTS


Please include the serial number of your pump when ordering spare parts. With this number we can
determine and duplicate the original configuration and materials of construction.

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10.0 SPECIAL SERVICE


The seal assembly is extremely important to the total, efficient operation of Wilfley A9 pumps. Its parts,
gaskets and seals must be in good working order. Many times parts are replaced unnecessarily due to
unfamiliarity with the assembly. The reverse is also true: parts that should be replaced are, at times, left in
the assembly. For these reasons, we provide the service of rebuilding this assembly in our factory.

Your Wilfley A9 pumps and seals may be returned to the factory, at any time, for complete overhaul and
repair. Each pump is completely disassembled and worn or inoperable parts are replaced. All rebuilt
pumps are subjected to the same testing procedures as newly constructed units. We charge the
standard price for parts and a minimal reassembly fee.

The utilization of this service provides you with almost instantaneous pump repair at an economical price.
The units are overhauled and returned to you quickly.

Please contact A.R. Wilfley and Sons, Inc. or any of our authorized representatives at any time concerning
our pumps or parts. You can be assured that we will do all within our power to ensure your complete
satisfaction with Wilfley products.

A.R Wilfley and Sons, Inc.


P.O. Box 2330
Denver, Colorado 80201
1-(303) 779-1777
1-(800) 525-9930
www.wilfley.com

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APPENDIX A – SHAFT WRENCH

Figure 25 – Shaft Wrench Drawing

Table 11 – A9 Nominal Shaft Diameters


NOMINAL SHAFT DIAMETER W X Y Z
0.875 1.375 0.958 0.878–0.880 0.188–0.192
1.125 1.625 1.253 1.128–1.130 0.125–0.129
1.625 2.125 1.806 1.628–1.630 0.375–0.379
1.750 2.5 1.940 1.753–1.755 0.375–0.379
2.375 3.25 2.690 2.378–2.380 0.625–0.629
DIMENSIONS ARE IN INCHES

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APPENDIX B – A9 Bolt Torque Values


Table 12 – A9 Bolt Torque Values
SAE Grade 2 (ft-lbs) SAE Grade 5 (ft-lbs)
Bolt Size TPI Torque Bolt Size TPI Torque
1/4 20 4 1/4 20 7
5/16 18 8 5/16 18 13
3/8 16 14 3/8 16 23
1/2 13 34 1/2 13 55
5/8 11 70 5/8 11 110
3/4 10 110 3/4 10 200
7/8 9 150 7/8 9 320
1 8 225 1 8 480
1-1/8 7 350 1-1/8 7 580
1-1/4 7 500 1-1/4 7 600*
1-3/8 6 550* 1-3/8 6 600*
1-1/2 6 600* 1-1/2 6 600*
1-3/4 5 600* 1-3/4 5 600*
2 4.5 650* 2 4.5 650*

18-8 and 316 Stainless (ft-lbs) METRIC Class 8.8 (ft-lbs)


1/4 20 4 6mm 1.00 4
5/16 18 8 8mm 1.00 12
3/8 16 14 10mm 1.25 30
1/2 13 34 12mm 1.25 40
5/8 11 70 14mm 1.25 65
3/4 10 110 16mm 2.00 100
7/8 9 150 18mm 2.00 135
1 8 225 22mm 2.50 210
1-1/8 7 350 24mm 3.00 315
1-1/4 7 500
1-3/8 6 550*
1-1/2 6 600*

Note: Lubricate all fastener threads before tightening.

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