Grundfos CR 95 Mode d'emploi
CR, CRN 95 to 255
50/60 Hz
Service instructions
GRUNDFOS INSTRUCTIONS
English (GB) Service instructions
Original service instructions
Table of contents
1. General information ........................4
1.1 Hazard statements..........................4
1.2 Notes ..................................4
1.3 Safety .................................5
1.4 Contaminated products .......................5
1.5 Servicing the motor .........................5
2. Preparing the dismantling of the product ..........5
2.1 Lifting the product ..........................5
3. Dismantling and assembling the product ..........6
3.1 Motor and coupling .........................6
3.2 Shaft seal, motor stool, pump head cover, sleeve and
chamber stack ............................6
3.3 Thrust-handling device ......................10
4. Renewing thrust-handling-device wear parts .......12
4.1 Chamber stack ...........................12
5. Renewing chamber wear parts ................16
5.1 Neck ring (45)............................16
5.2 Bush (47c) and retaining ring (47d) ...............18
6. Renewing shaft seal wear parts ...............18
6.1 Dismantling .............................18
6.2 Assembly ..............................19
7. Additional information .....................20
7.1 Torques ...............................20
7.2 Lubricants ..............................20
7.3 Special service tools........................21
7.4 Order of assembly for chambers and impellers........23
7.5 Drawings...............................24
8. Document quality feedback ..................30
1. General information
Read this document before you install the product.
Installation and operation must comply with local
regulations and accepted codes of good practice.
1.1 Hazard statements
The symbols and hazard statements below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
DANGER
Indicates a hazardous situation which, if not avoided, will
result in death or serious personal injury.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate personal injury.
The hazard statements are structured in the following way:
SIGNAL WORD
Description of the hazard
Consequence of ignoring the warning
• Action to avoid the hazard.
1.2 Notes
The symbols and notes below may appear in Grundfos installation
and operating instructions, safety instructions and service
instructions.
Observe these instructions for explosion-proof products.
A blue or grey circle with a white graphical symbol
indicates that an action must be taken.
A red or grey circle with a diagonal bar, possibly with a
black graphical symbol, indicates that an action must not
be taken or must be stopped.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
Tips and advice that make the work easier.
4
English (GB)
1.3 Safety
DANGER
Electric shock
Death or serious personal injury
‐Switch off the power supply before you start any work
on the product.
‐Make sure that the power supply cannot be switched
on accidentally.
WARNING
Falling objects
Death or serious personal injury
‐Follow the lifting instructions.
‐Use lifting equipment which is approved for the weight
of the product.
‐Keep the product in a stable and fixed position when
working on it.
‐Persons must keep a safe distance to the product
during lifting operations.
‐Wear personal protective equipment.
For lifting instructions, see the instructions provided with the
product.
WARNING
Corrosive liquids
Death or serious personal injury
‐Wear personal protective equipment.
WARNING
Toxic liquids
Death or serious personal injury
‐Wear personal protective equipment.
CAUTION
Hot or cold liquid
Minor or moderate personal injury
‐Wear personal protective equipment.
CAUTION
Hot or cold surface
Minor or moderate personal injury
‐Make sure that no one can accidentally come into
contact with hot or cold surfaces.
We recommend that you repair pumps with motors of 7.5 kW and
up at the pump site. Necessary lifting equipment must be available.
1.4 Contaminated products
CAUTION
Biological hazard
Minor or moderate personal injury
‐Flush the pump thoroughly with clean water and rinse
the pump parts in water after dismantling.
The product will be classified as contaminated if it has been used
for a liquid which is injurious to health or toxic. If you request
Grundfos to service the product, contact Grundfos with details
about the pumped liquid before returning the product for service.
Otherwise, Grundfos can refuse to accept the product for service.
Any application for service must include details about the pumped
liquid.
Clean the product in the best possible way before you return it.
Costs of returning the product are to be paid by the customer.
1.5 Servicing the motor
Grundfos MG and MGE motors
Service documentation is available in Grundfos Product Center at
http://product-selection.grundfos.com/.
Motors of other makes
Contact the motor manufacturer.
2. Preparing the dismantling of the product
2.1 Lifting the product
Lifting procedures are described in the installation and operating
instructions. Use the QR code or link below:
http://net.grundfos.com/qr/i/99078486
5
English (GB)
3. Dismantling and assembling the product
Parts are indicated by numbers and refer to the drawings in the
section on drawings.
Tools are indicated by letters and refer to the section on special
service tools.
Related information
7.3 Special service tools
7.5.1 Overview of drawings
7.5.2 Exploded views
7.5.3 Sectional views
3.1 Motor and coupling
3.1.1 Removal
1. Disconnect the power supply and remove the power cable.
2. Remove screws (7a) and coupling guards (7).
3. Remove screws (9) and coupling halves (10a). It may be
necessary to gently loosen the coupling halves with a plastic
hammer.
4. Remove the cylindrical pin (10) from the pump shaft (51).
5. Attach approved lifting equipment to the motor to prevent it from
falling before proceeding with any further dismantling. For
correct attachment of lifting equipment, see instructions supplied
with the pump.
6. Remove the screws (28), washers (32) and nuts (36).
7. Carefully lift the motor off the pump using approved lifting
equipment. For lifting the motor correctly, see the instructions
supplied with the pump.
3.1.2 Installation
1. Carefully lift the motor onto the motor stool (1a) using approved
lifting equipment.
2. Install the screws (28), washers (32) and nuts (36).
3. Lubricate and tighten the nuts (36) to the specified torque.
4. Install the cylindrical pin (10) in the pump shaft (51).
5. Install the coupling halves (10a).
6. Lubricate and cross-tighten the screws (9).
7. Install the coupling guards (7) and tighten the screws (7a).
Related information
7.1 Torques
7.2 Lubricants
3.2 Shaft seal, motor stool, pump head cover, sleeve
and chamber stack
3.2.1 Preparations
1. Remove the motor as described in the section on motor and
coupling removal.
2. Close the isolating valves, if fitted, to avoid draining the pipe
system.
3. Drain the pump by loosening the vent screw (18) and removing
the plugs (25) and O-rings (38).
Related information
3.1.1 Removal
3.2.2 Dismantling
1. Clean the end of the shaft (51) with a cloth.
2. If the shaft seal (105) is to be reused, remove any marks or
scratches on the shaft (51) by using service tool E together with
a piece of fine emery cloth.
3. Loosen the three set screws (113) of the shaft seal (105). Note
that the set screws must be loosened no more than 1/4 turn.
4. Loosen the shaft seal by using service tool A, together with
service tools O and P.
5. Carefully lift the shaft seal (105) off the shaft (51). Note that the
shaft seals fitted on pumps with ∅28 and ∅36 pump shafts can
be fitted with new wear parts. See the section on renewing shaft
seal wear parts.
6. Attach approved lifting equipment to the motor stool (1a) to
prevent it from falling before proceeding with any further
dismantling.
7. Remove nuts (36) and washers (66a).
8. Remove the motor stool (1a).
9. Remove the pump head cover (2). It may be necessary to
loosen it from the sleeve (55) using a plastic hammer.
10. Remove the O-ring (37) from the pump head cover.
11. Pull out the outlet part (44a) from the pump head cover (2).
12. CR pumps only: Remove the four screws (2d) and the brackets
(2c) from the pump head cover (2).
13. Fit service tool N on the pump sleeve (55). See the figure below.
TM071740
Service tool N fitted on sleeve (55)
14. Attach approved lifting equipment to service tool N and lift the
sleeve (55) up and away from the chamber stack.
6
English (GB)
15. Fit service tool B in the top of the pump shaft.
When handling the chamber stack, it is important to
pay close attention in order not to damage the thrust-
handling device (120), if fitted.
16. Attach approved lifting equipment to service tool B and lift up the
chamber stack.
TM071900
Lifting the chamber stack
17. Lay down the chamber stack in a fixed position so that it cannot
move.
18. Remove the O-ring (37) from the pump base.
Related information
6. Renewing shaft seal wear parts
7.3.1 Special tools
3.2.3 Assembly
1. Lubricate and install a new O-ring (37) in the pump base (6).
See the section on lubricants.
2. Carefully lift the chamber stack with approved lifting equipment
and lower it into the pump base.
Make sure to align the pump inlet part (44) with the tap in the
pump base (6). See the figure below.
TM071742
Aligning inlet part (44) in pump base (6)
3. Fit service tool N on the pump sleeve (55).
4. Attach approved lifting equipment to service tool N and lift the
sleeve (55) onto the pump base (6).
Make sure to align the sleeve (55) according to the alignment
marks on the sleeve (55) and on the pump base (6). Also
ensure that the sleeve (55) is pressed fully home in the pump
base (6).
TM070849
Aligning sleeve (55) in pump base (6)
5. Lubricate and install a new O-ring (37) in the pump head cover.
See the section on lubricants.
6. CR pumps only: Install the four screws (2d) and the brackets
(2c) in the pump head cover (2). See the section on torques.
7. Install the outlet part (44a) in the pump head cover (2).
7
English (GB)
8. Install the pump head cover (2) on the sleeve (55). Use service
tool J to centre the chamber stack in the pump head cover (2).
See the figure below.
TM071901
Fitting service tool Jin the pump head cover (2).
Make sure to align the pump head cover (2) according to the
alignment marks on the pump head cover (2) and on the sleeve
(55). See the figure below.
TM071741
Aligning pump head cover (2) and sleeve (55)
9. Attach approved lifting equipment to the motor stool (1a) and lift
the motor stool (1a) onto the pump head cover (2).
10. Install washers (66a) and nuts (36).
11. Lubricate the threads of the staybolts (26) and cross-tighten the
nuts (36) to the specified torque. See the sections on torques
and lubricants.
12. Remove service tool J.
13. Clean and smooth the shaft (51) using service tool E with an
emery cloth supplied with the shaft seal kit.
14. Lubricate the O-rings in the shaft seal (105). See the section on
lubricants.
Avoid lubrication on the seal faces.
15. Install the shaft seal (105) on the shaft (51) and press it home
against the pump head cover (2).
16. Tighten the shaft-seal hexagon nut to the specified torque by
using service tool A, together with service tools O and P. See
the section on torques.
8
English (GB)
17. Check that the height X is maximum 71 mm. See the figure
below.
If the measured height is not within the specifications, the pump
has not been assembled correctly, and the pump must be
dismantled to find the reason.
TM070969
X: 69 ± 2 mm
Note that the below text applies only for pumps with motor sizes
75 to 200 kW (100-300 hp) and fitted with a thrust-handling
device.
During assembly of the pump, there is a risk that the O-ring
(120i) causes the stationary ring (120g) to stick. As a result, the
entire chamber stack will not be fully seated inside the pump.
This can lead to malfunction and eventually damage to the
pump if it is started. See the figure below.
120g
120i
TM083369
Before making the shaft height adjustment, make sure the shaft
with impellers is placed as much downwards as possible inside
the pump. This can be checked by rotating the shaft by means
of a screwdriver inserted in the cross-hole at the top of the shaft.
TM083256
• If the friction is with high scattering or peaks caused by the
axial metal-to-metal contact between impeller and chamber,
then the shaft with impellers is positioned correctly and you
can go on with the shaft height adjustment using the
adjustment fork.
• If rotating freely with very little friction, try rotating CCW and
CW until the shaft binds and you feel the metallic contact
between the chambers and impellers.
• If you cannot feel the metallic contact between the chambers
and impellers, the pump must be disassembled, and the
stationary ring (120g) must be pressed fully down in the
pump base so that it is seated completely against the lifting
plate (120h) and the flange (120k).
18. Install the cylindrical pin (10) in the pump shaft (51).
19. Install the coupling halves (10a).
20. Lubricate and tighten the screws (9), but leave loose. See the
section on lubricants.
21. Check that the gaps on either side of the coupling halves are
equal. See the figure below.
TM071744
Gap between coupling halves
22. Tighten the three set screws (113) to the specified torque. See
the section on torques.
23. Lift the pump shaft with a crowbar and insert the adjusting fork
F. See the figure below.
TM070868
Lifting pump shaft and fitting adjusting fork.
24. Cross-tighten the screws (9) to the specified torque. See the
section on torques.
9
English (GB)
25. Pull the adjusting fork F free of the shaft (51) and place it on the
backside of one of the coupling guards (7). See the figure
below.
TM071743
Fitting adjusting fork Fon the backside of coupling guard (7)
26. Install the coupling guards (7) and tighten the screws (7a). See
the section on torques.
Related information
7.1 Torques
7.2 Lubricants
7.3.1 Special tools
3.3 Thrust-handling device
This section applies only for pumps fitted with a thrust-handling
device (120).
All parts for the thrust-handling device must be handled
very carefully in order to avoid damaging them.
There are two ways to service the thrust-handling device:
• by completely dismantling the entire pump.
See instructions in the section on servicing the thrust-handling
device by dismantling the entire pump.
• by positioning the pump horizontally and accessing the thrust-
handling device from the pump base.
See instructions in the section on servicing the thrust-handling
device from the pump base.
Related information
3.3.1 Servicing the thrust-handling device by dismantling the entire
pump
3.3.3 Servicing the thrust-handling device from the pump base
3.3.1 Servicing the thrust-handling device by dismantling the
entire pump
Preparations
Removing the thrust-handling device requires that the pump has
been dismantled as described in the sections on removal of the
motor and coupling and dismantling of the shaft seal, motor stool,
pump head cover, sleeve and chamber stack.
Dismantling
1. Lay down the chamber stack on a solid surface and take the
necessary precautions to prevent the chamber stack from
moving while working on it.
2. Loosen and remove the nut (120f) and washer (120e). Note that
the nut features a left-handed thread. Use service tools C, D, O
and P to hold the shaft when loosening the nut (120f).
D C O P
TM071746
Dismantling thrust-handling device from pump shaft
3. Remove thrust-handling-device wear parts (120a,120b, 120c,
120d). The parts come out together.
4. Remove the stationary ring (120g) together with the lifting plate
(120h) by using service tool G for pulling out the parts.
TM071745
Removing stationary ring (120g) and lifting plate (120h)
5. Remove the bolts (26b) from the pump base (6).
6. Remove the flange (120k) by using two bolts (26b) as
extractors.
26b
TM071747
Extracting the flange
10
English (GB)
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