Dec Manual

TOYO PUMPS NORTH AMERICA CORPORATION
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
TITLE: DEC/DBC INSTALLATION, OPERATION AND DOCUMENT NO: TED-051 REV. NO: SHEET 1 OF 39
MAINTENANCE MANUAL
PREPARED BY: KSH DATE: MAY 1 1997
APPROVED BY: DATE: SUPERSEDES:
EFFECTIVE: PUMP SERIAL NUMBER:
TABLE OF CONTENTS
SECTION 1.0 INTRODUCTION
SECTION 2.0 TECHNICAL DATA SHEET
2.1 CUSTOMER FILL IN DATA SHEET
SECTION 3.0 WARRANTIES
SECTION 4.0 SAFETY
SECTION 5.0 INSTALLATION
5.1 CHECK UPON ARRIVAL
5.2 STORAGE
5.2.1 NEW PUMP AND EQUIPMENT STORAGE

5.2.2 USED PUMP STORAGE
5.2.3 SPARE PARTS STORAGE
5.3 HANDLING
5.4 ALIGNMENT
5.5 MOUNTING
5.6 SUCTION AND DISCHARGE PIPING
5.7 POWER SUPPLY
SECTION 6.0 OPERATION
6.1 ROTATION
6.2 START UP
1 457 ITEM NUMBER UPDATE (ITEMS 391, 256, 205, AND 910 REVISED) KSH JRH 28/07/97
REV ECN CHANGE DESCRIPTION BY APPV’D DATE

MAINTENANCE MANUAL
TABLE OF CONTENTS (ctd)

SECTION 7.0 MAINTENANCE
7.1 INSPECTION AND ADJUSTMENT FOR WEAR
7.2 LUBRICATION
7.2.1 START UP
7.2.2 RE-GREASING INTERVALS
7.3 TROUBLE SHOOTING
SECTION 8.0 BEARING FRAME ASSEMBLY
8.1 SHAFT PRE-ASSEMBLY

8.2 BEARING HOUSING PRE-ASSEMBLY
8.3 SHAFT INSTALLATION
8.4 BEARING ISOLATOR ASSEMBLY
SECTION 9.0 WET END ASSEMBLY
9.1 BASEPLATE INSTALLATION

9.2 COLUMN AND IMPELLER INSTALLATION
9.2.1 AGITATOR OPTION

9.2.2 NON-AGITATOR OPTION
9.2.3 CUTTER OPTION
9.3 CASING AND SUCTION HARDWARE INSTALLATION

9.3.3 CUTTER OPTION

MAINTENANCE MANUAL
TABLE OF CONTENTS (ctd)
SECTION 10.0 APPENDIX
10.1 BOLT TORQUE TABLE

10.2 TOOL LIST
10.3 DIMENSION TABLE
10.4 PUMP PERFORMANCE DATA
10.4.1 PUMP PERFORMANCE CURVE

10.4.2 CRITICAL SPEED CURVE
10.5 BEARING FRAME ASSEMBLY DRAWING

10.6 PUMP ASSEMBLY DRAWING
10.7 PUMP GENERAL ARRANGEMENT DRAWING – OPTIONAL
10.8 PARTS LIST
10.9 AUXILIARY EQUIPMENT
10.9.1 ELECTRIC MOTOR INFORMATION

10.9.2 COUPLING INFORMATION
10.9.3 GEAR REDUCER INFORMATION

MAINTENANCE MANUAL
TABLE OF DRAWINGS
Drawing B____: Shaft Pre-Assembly................................................................................................. 17

Drawing B____: Bearing Housing Pre-Assembly ............................................................................ 20
Drawing B____: Shaft Installation....................................................................................................... 23
Drawing B____: Bearing Isolator Assembly...................................................................................... 24
Drawing B____: Baseplate Installation.............................................................................................. 27
Drawing B____: Column and Impeller Installation - Agitator Option............................................... 28
Drawing B____: Column and Impeller Installation - Non-Agitator Option....................................... 31
Drawing B____: Column and Impeller Installation - Cutter Option .................................................. 32
Drawing B____: Casing, Strainer and Agitator Installation - Agitator Option................................ 33
Drawing B____: Casing, Strainer and Agitator Installation - Non-Agitator Option........................ 36
Drawing B____: Casing, Strainer and Agitator Installation - Cutter Option ................................... 37
Drawing B____: Discharge Pipe Installation..................................................................................... 38

MAINTENANCE MANUAL
1.0 INTRODUCTION
Your new Toyo cantilever pump has been designed and manufactured to perform for many years with
a minimum of maintenance. However, parts will wear and need replacing sooner or later. The time
period between maintenance will greatly depend on the service and your maintenance program.
This manual has been compiled to help you minimize your maintenance and speed repairs when
required. Read and understand this manual.
Please provide the Serial Number of your equipment If additional manuals are needed.
In Section 2.0 of the manual you will find a “Technical Data Sheet”. Most of this sheet will be filled in
at Toyo. However, there may be sections that are left blank. It is advisable to fill in these sections for
future reference.
NOT ALL PUMPS ARE OF STANDARD CONFIGURATION
WHEN ORDERING PARTS ALWAYS REFER TO PUMP SERIAL NUMBER. THIS NUMBER IS
FOUND ON THE NAME PLATE ON THE PUMP AND ON THE “TECHNICAL DATA SHEET” OF
THIS MANUAL.

MAINTENANCE MANUAL
2.0 TECHNICAL DATA SHEET
CUSTOMER :
LOCATION :
APPLICATION :
PUMP MODEL :
PUMP SERIAL NUMBER :
METALLURGY :
OPERATING CONDITIONS
FLOW (USGPM)
NORMAL :
MAX. :
MIN. :
TDH (FEET) :
SLURRY S.G. :
SOLIDS % BY VOLUME :
MAX. PARTICLE SIZE (IN.) :
TEMPERATURE(ºF) :
pH :
PUMP DATA
PUMP SPEED (RPM) :

IMPELLER DIA. (IN.) :
BEARING FRAME :
ASSEMBLY WEIGHT :
FOR COMPLETE PUMP DATA SHEET SEE SECTION 10.0

MAINTENANCE MANUAL
2.1 CUSTOMER FILL IN DATA SHEET
START-UP OPERATING CONDITIONS
FLOW (USGPM) NORMAL :

MAX. :
MIN. :
DISCHARGE PRESSURE (PSI) :
SLURRY S.G. :
SOLIDS % BY VOLUME :
MAX. PARTICLE SIZE (IN.) :
TEMPERATURE :
pH :
START-UP PUMP DATA
PUMP SPEED (RPM) :
POWER DRAW (AMPS) :
OIL TEMPERATURE (°F) :
NOTES :

MAINTENANCE MANUAL
3.0 WARRANTIES
Seller warrants that the products covered by this contract conform to applicable drawings and
specifications accepted in writing by Seller, will be free from defects in material and workmanship,
will be merchantable and will perform in accordance with the detailed specifications accepted in
writing by Seller. These warranties extend for a period of twelve (12) months from the date of
installation or eighteen (18) months from the date of shipment, whichever occurs first. Buyer’s
exclusive remedy and Seller’s sole duty under these warranties is to repair or replace the product.
Normal wear and tear on Seller’s product shall not constitute a warranty defect. THERE ARE NO
OTHER WARRANTIES, EXPRESSED OR IMPLIED, WHICH EXTEND BEYOND THOSE SET
FORTH ABOVE. THE WARRANTY OF MERCHANTABILITY IS LIMITED TO THE TIME PERIOD
SPECIFIED ABOVE. These warranties are contingent upon the product being stored, installed,
maintained, and operated in accordance with good engineering practices and the instructions
contained in the Operating and Maintenance Manual.
Seller’s total responsibility for damages whether arising in contract or tort arising out of or relating to
its performance of this contract or the products covered hereunder shall be limited to the contract
price for the product. In no event shall Seller be liable for any incidental or consequential damages
such as lost profits, loss of use of productive facilities or equipment, expenses or damages incurred
in reliance on Seller’s performance hereunder or lost production whether suffered by buyer or any
third party
Seller will be responsible for compliance with federal, provincial and municipal laws, codes, and
regulations relating to the manufacture of the products. Seller warrants that the products comply with
OSHA standards on drive guard design and construction in effect at the time of manufacture and
makes no other warranty with respect to any other standards. Seller shall not be responsible for
failure of parts to fit properly due to deterioration of or modification to Buyer’s existing equipment for
which such parts are furnished. Seller makes no warranty or guarantee that the equipment or parts
supplied hereunder will comply with any existing performance of Buyer’s equipment.
Seller reserves the right to furnish substitutes for material not available or whose use is restricted,
provided such substitute material is of equal quality and performance.

MAINTENANCE MANUAL
4.0 SAFETY
Do not install the equipment other than in accordance with the instructions contained in this manual.
When required information can not be found in this manual, contact the nearest TOYO branch office.
This instruction book should be read completely before starting installation, maintenance or
operation. The equipment is capable of trouble free operation when properly installed, operated and
maintained. These instructions present the basic information and methods required for proper
installation and maintenance.
This pump has been designed to provide safe and reliable service, however it is both a pressure
vessel and a piece of rotating machinery. The operator(s) must exercise good judgment and proper
safety practices to avoid damage to the equipment and surroundings and to avoid personal injury.
The instructions in this manual are intended for personnel with a general training in operation and
maintenance of centrifugal pumps.
It is assumed that your safety department has established a safety program based upon a thorough
analysis of industrial hazards. Before installing, operating or performing maintenance on the pump
and associated components described in this manual, it is suggested that the safety program is
reviewed to ensure that it covers the hazards arising from high speed rotating machinery. In general,
all personnel should be guided by all the basic rules of safety associated with the equipment and the
process.
It should be understood that the information contained in this manual does not relieve operating and
maintenance personnel of the responsibility of exercising normal good judgment in operation and
care of the pump and its components.
TOYO Pumps reserves the right to change the design, construction or material of any part without
incurring the obligation of installing such changes on pumps already delivered.
5.0 INSTALLATION

MAINTENANCE MANUAL
5.1 CHECK UPON ARRIVAL
The unit must be inspected immediately upon arrival and any irregularities and damages due
to shipment must be reported to the carrier and TOYO pumps. A copy of this manual as well
as instruction sheets for other equipment (such as drive components etc.) are included in the
shipment. Put these papers in a safe, accessible place for ready reference when required. It
is important that the entire contents of this manual are studied before installation.
Pump parts and accessories may be packed inside shipping container, or attached to skids in
individual packages. Inspect all containers, crates and skids before discarding.
5.2 STORAGE
5.2.1 NEW PUMP AND EQUIPMENT STORAGE
If your new pump is to be stored for a long period of time before use, the following
procedures must be adhered to in order for TOYO to extend the normal warranties.
Notify TOYO that the equipment is to be stored and that the storage procedures will be
followed. Depending on size and type of equipment a visual inspection may be
required.
Notify TOYO when equipment is to be removed from storage and put into service.
Failure to notify TOYO will result in your warranty being void.
Your new pump will arrive lubricated, ready for use. A small amount of grease or
suitable protectant must be applied to all exposed, unpainted metal surfaces such as
shaft drive end, shaft sleeve etc.
Suitable covers out of plywood or plastic must be installed on the suction and discharge
flanges and any other openings on auxiliary equipment to provide adequate protection
against dirt, dust and nesting animals.

MAINTENANCE MANUAL
5.2.1 (ctd.)
Equipment should be stored in a dry location and situated on an even surface with no
strains applied. If stored outdoors, the equipment must be covered with a waterproof
tarp secured to the equipment or skid. During storage, rotating equipment shafts must
be rotated by hand to relubricate the bearing surfaces and to prevent the bearings from
being damaged.
ROTATE ONCE A MONTH
5.2.2 USED PUMP STORAGE
A used pump should be completely disassembled and all parts cleaned and inspected.
All unpainted metal surfaces should be coated with grease or suitable protectant. All
previously painted parts should be touched up or repainted. Reassemble the pump as
per Sections 8.0 and 9.0 and store as per Section 5.2.1.
5.2.3 SPARE PARTS STORAGE
Spare parts may arrive at your site without adequate protection for long term storage
unless it was specified in your parts order. It is the customers responsibility to ensure
that all spare parts are prepared and packaged for long term storage. Components
such as bearings, mechanical seal assemblies and parts should be left in their original
sealed containers. The long term storage of elastomer (rubber) parts must be given
consideration since elastomers may have a short shelf live under certain
circumstances.
5.3 HANDLING
Use care when moving pumps. Rough handling can cause breakage or permanent
misalignment. Sling pumps so that any protruding components will not be damaged. Do not
use choke type sling or chain arrangements for skids or containers. Make sure that the lifting
equipment is rated to safely handle the weight of the pump and auxiliary equipment.
See Section 2.0, TECHNICAL DATA SHEET for weight information.


MAINTENANCE MANUAL
5.4 ALIGNMENT
The pump was checked during assembly and testing for proper alignment of the drive
equipment. Handling during shipment, storage or preparation for installation could have
caused distortions. For direct or gear reducer driven units, the alignment must be verified
upon installation prior to start-up. Follow the drive manufacturers instructions and tolerances
for angular and parallel alignment.
5.5 MOUNTING
The anchor bolts should be sized to approximately 1.5 mm (1/16”) smaller than mounting holes
provided on the pump baseplate. These bolts will not be subject to shear and therefore should
be the type that will resist pull out. Ideally the bolts should be set in the concrete.
If a pump is to be mounted on a steel frame, the frame must be of sufficient member depth and
strength to support the pump weight and dynamic load between a given span. The mounting
bolts should be sized 1.5 mm (1/16”) smaller than the mounting holes in the baseplate. The
mounting bolts should be Grade 6.4 (ANSI Grade 5) or better.
5.6 DISCHARGE PIPING
The discharge piping should be of proper wall thickness and diameter to handle flows and
pressures required for your pump. The pump flanges will be drilled for proper ANSI bolt
pattern for pipe size and pressure. All piping should be independently supported. The pump
casing should never bear the weight of the piping (the pump casing may break and later
removal of casing would be difficult). Flexible pipe or expansion type joints are recommended
provided that they are of non-collapse type.
5.7 POWER SUPPLY
The power supply should be as per local and national codes. All wiring and installation of
disconnects, etc., should be performed by qualified personnel.

MAINTENANCE MANUAL
6.0 OPERATION
6.1 ROTATION
After your pump is installed properly, you must check for proper rotation.
DISCONNECT ALL DRIVE EQUIPMENT
If you check the rotation with drive equipment connected and the rotation is incorrect, the
impeller connective components may INSTANTLY UNSCREW causing serious damage to
pump. When viewed from the suction end, rotation is counter clockwise. At this point, rotate
the shaft by hand to check the impeller clearance. If you have the proper motor rotation and
impeller clearance, the pump is now ready to be started. If the impeller clearance needs
adjustment, refer to Section 9.2. Install and tighten the belts or couplings. Install all guards.
6.2 START UP
During the first few days of operation while all the parts are still new, observe the discharge
gage readings as well as the motor amperage. If a flow meter is available monitor the pump
output as well.
Record these readings in the CUSTOMER FILL IN DATA SHEET provided in Section 2.1 for
future reference.
These readings should be taken and recorded periodically and will help you to establish an
inspection and maintenance schedule. Keeping track of your pump’s performance will make it
easier to identify problems before they become serious and cause undue damage.

MAINTENANCE MANUAL
7.0 MAINTENANCE
7.1 INSPECTION & ADJUSTMENT FOR WEAR
After your pump has been in service for awhile, the impeller, casing and delivery cover will
become worn causing the pump to lose efficiency. The speed with which these parts will wear
will depend on the material and concentration being pumped.
As noted in the Section 6.0, the discharge pressure, as well as the flow and AMP draw should
have been recorded on the Customer Fill In Data Sheet located in Section 2.1 of this
manual.
By comparing the original data with your current readings, the wear and efficiency of your
pump can easily be determined. The output flow and pressure dropping off with an increase in
amperage draw on the motor signals wear of the wet end components requiring adjustment.
After the pump has been adjusted several times, the wet end parts should be visually
inspected.
7.2 LUBRICATION
The cantilever pump bearings are grease lubricated. A sufficient amount of grease has been
used during the initial assembly to charge the bearings. Grease fittings have been provided to
allow re-greasing of the bearings. Toyo will be using an SKF NLGI class 3 high temperature
grease. The following is a list of comparable greases by some common manufacturers.
MANUFACTURE LUBRICANT TEMPERATUR PRODUCT

R E CODE
SHELL DARINA XL2 -45°C TO 160°C 504-547
PETRO CANADA MULTIPURPOSE EP2 -30°C TO 135°C
MOBIL OIL MOBILITH SHC 100 <150°C 64407-0
CHEVRON CHEVRON ULTI-PLEC EP <150°C
IMPERIAL OIL UNIREX N (GRADES 2 AND 3) <150°C
SKF LGHQ 3/18 -30°C TO 150°C

MAINTENANCE MANUAL
7.2.1 START UP
A short period of running time, on initial start up, is required to allow the bearings to
“Run In” and the bearing temperatures to stabilize.
During this “Run In” time, grease may be added through the grease fittings. The
bearing housing temperature should be monitored since over greasing is the leading
cause of excess bearing heat. The bearing housing temperature will stabilize after the
first half hour of operation at constant load and speed.
Since bearing temperatures will vary with the operating point of the pump, no specific
operating temperature can be given. However, no bearing should exceed 150 °C (302
°F) to prevent property changes in the bearing materials (120 °C for polyamide caged
bearings).
7.2.2 RE-GREASING INTERVALS
The bearings should be re-greased with the pump running to allow the bearings to
centrifuge out old and excess grease. Grease life varies considerably, dependent on
bearing size, type, rotational speed, operating temperature, and by the ingress of
moisture, gases and foreign matter.
Toyo generally recommends an initial re-grease interval not exceeding one month. This
interval may be lengthened or shortened with the discretion of an experienced operator.
If the bearings are frequently being splashed with liquid, the re-grease interval should
not exceed one week unless marine grease is being used.
Re-greasing intervals will vary depending on the installation. Generally, when the
operating temperature is over 80 °C (176 °F), the re-grease interval should be halved
for every 15 °C (27 °F) rise in operating temperature.

MAINTENANCE MANUAL
7.2.2 (ctd)
At least annually, or more frequently if the re-grease interval is short, the bearing
housing should be opened. The housing should be cleaned of accumulated old grease,
and the bearings washed in a clean solvent, blown dry, examined, re-installed and re-
greased. Refer to Section 8.0 in this manual.
Caution: Do not re-use bearings that have obvious visual defects or that have been
discolored to a light blue. Examine any seals for wear during all bearing housing
disassemblies.
7.3 TROUBLE SHOOTING
• PUMP WILL NOT BUILD PRESSURE
Wet end is worn and needs adjustment.
• PUMP WILL NOT PUMP NORMAL VOLUME
Wet end is worn and needs adjustment.
NOTE: Loss of flow may be compensated by increasing the operating speed; however, care
should be taken since an increase in speed could cause the pump to operate too close to its
critical speed. Refer to the Pump Critical Speed Curve in Section 10.6 of the appendix to
verify that the pump can operate acceptably before increasing the speed. This is a short term
solution only since the increase in speed will increase the rate of wear.

TITLE: 5E BEARING HOUSING: INSTALLATION, DOCUMENT NO: REV. NO: 1 SHEET 18 OF 39

OPERATION AND MAINTENANCE MANUAL TED-054
PREPARED BY: KSH DATE: MAY 1, 1997
8.0 BEARING FRAME ASSEMBLY
Inspect and inventory all the parts before you begin assembly. Clean the parts and remove any burrs
as required. Assembly of the bearing frame should be performed in a clean, dust free area. Read
these instructions and drawings before you begin.
8.1 SHAFT PRE-ASSEMBLY
Refer to Drawing B3811
Position the Shaft (Item 201) in a horizontal position on a pair of notched wooden blocks or
similar support.
Preheat the Cylindrical Roller Bearing Inner Race (Item 073) to 100° C (212° F) in an oven or
heated oil bath and slide onto the shaft. For proper seating, position the bearing race against
the shaft shoulder and hold it in place while the race cools.
NEVER USE AN OPEN FLAME TO HEAT BEARINGS
Caution: Do not heat any bearing above 150° C (257° F) or permanent changes to the
bearing material may occur. Always wear fireproof insulated gloves when handling heated
components.
Position the Thrust Bearing Housing (Item 311) with the lip seal socket facing up on a flat
working surface.
Apply a thin film of a silicone type lubricant to the periphery of the Lip Seal (Item *2).
Position the seal, with the sealing lip down, into the lead-in chamfer and push it into the socket
using a proper installation tool.
Install the outer O-Ring (Item *1) onto the thrust bearing housing in the o-ring groove.


8.1 (ctd)
Slide the thrust bearing housing onto the shaft such that the flange face is past the bearing
seating shoulder on the shaft. Support the thrust bearing housing to ensure that the lip seal
does not get damaged.
Preheat the Angular Contact Ball Bearings (Item 072) to 100° C (212° F) in an oven or a
heated oil bath.
THE THRUST BEARINGS SHOULD BE INSTALLED IN A BACK TO BACK

CONFIGURATION. REFER TO THE DRAWING IF UNSURE OF THE PROPER BEARING
ORIENTATION
Remove one bearing from the oven and slide it onto the shaft, and hold the bearing against the
shaft shoulder as it cools to ensure proper seating. Remove the second bearing from the
oven, slide it onto the shaft, and hold it flush with the first bearing as it cools to ensure proper
seating.
Position the Bearing Lock Washer (Item 079.1) on the shaft and Install Bearing Lock Nut (Item
079.2). After the bearing lock nut has been tightened, bend one of the lock washer tabs into
an aligned groove on the lock nut.
Hand pack the bearings with grease.
After the bearings have cooled to ambient temperature slide the thrust bearing housing over
the bearings.
Insert a lifting eye bolt into the drive end of the shaft for further assembly. Cover and seal the
open end of the thrust bearing housing with a suitable material such as plastic foil or oil paper
to protect it from dust and dirt for intermediate storage between assembly steps.


8.2 BEARING HOUSING PRE-ASSEMBLY
For bearing frame assemblies equipped with a bearing isolator, skip to the next paragraph.
Position the Radial Bearing Housing (Item 301) with the lip seal socket facing up on a flat
working surface. Apply a thin film of a silicone type lubricant to the periphery of the Lip Seal
(Item *4). Position the seal, with the sealing lip down, into the lead-in chamfer and push it into
the socket using a proper installation tool.
Insert the Grease Retainer (Item 303) into the Bearing Housing (Item 331) until the grease
retainer bottoms on the shoulder in the bearing housing.
Pre-cool the Cylindrical Roller Bearing Outer Race and Roller Assembly (Item 073) in a
freezer.
Remove the bearing from the freezer, and insert it into the bearing housing. Hold the bearing
in place while it reaches ambient temperature to ensure proper seating. Hand pack the
bearing with grease.
Install the outer O-Ring (Item *3) onto the radial bearing housing in the o-ring groove on the
flange.
Apply a thin film of a silicone type lubricant to the inside of the bearing housing and the outside
of the radial bearing housing pilot diameters. Slide the radial bearing housing into the bearing
housing. Align the tapped holes in the radial bearing housing with the holes in the bearing
housing.
Apply a small amount of “Never-seez” or similar compound to the hex head cap screws (Item
*5). Install the hex head cap screws and tighten in a criss-cross fashion to the required torque
value.
Note: For required torque values refer to the torque table in Section 10.0.
Install the Pressure Relief Fitting (Item 030.1). Install and charge the Grease Fitting (Item
030.2).


8.3 SHAFT INSTALLATION
Position the Thrust Bearing End Cover (Item 315) with the lip seal socket facing up on a flat
working surface. Apply a thin film of a silicone type lubricant to the periphery of the Lip Seal
(Item *6). Position the seal, with the sealing lip down, into the lead-in chamfer and push it into
the socket using a proper installation tool. Install and charge the Grease Fitting (Item 030.3).
Position Bearing Housing in a vertical position, with the radial bearing housing side down, on
a suitable stable support. Apply a thin film of a silicone type lubricant to the outside diameter
of the thrust bearing housing and the o-ring. Pick up the shaft pre-assembly by the lifting eye
bolt and position over the outboard bearing bore. Lower the shaft into the housing slowly,
taking care not to damage the lower lip seals, until the thrust bearing housing is seated against
the bearing housing. Align the holes in the thrust bearing housing with the holes in the bearing
housing. Tap the end of the shaft with a rubber hammer to ensure proper seating of the shaft
assembly.
Note: Bearing Housing weights are given in Section 10.0.
Slide the thrust bearing end cover over the shaft. Snug the Hex Head Cap Screws, Nuts and
Washers (Items *7, *8, *9). Measure the gap between the thrust bearing end cover and the
thrust bearing housing and remove the thrust bearing end cover.
Prepare a Shim Kit (Item *11) whose thickness is no greater and up to 0.025 mm (0.001 in)
less than the measured gap. The shims have two extra holes so that removal of the thrust
bearing end cover using the jacking bolt holes will not damage the shims. Slide the shims
over the shaft so that these extra holes are located 90° away from the jacking bolt holes in the
thrust bearing housing.
Re-install the thrust bearing end cover, ensuring that the jacking bolt holes in the thrust bearing
end cover and the thrust bearing housing are offset by 90 degrees as shown in figure 8.3.3.
Apply a small amount of “Never-seez” or similar compound to the hex head cap screws, re-
install the fasteners, and tighten the hex head cap screws and nuts.


8.3 (ctd)
Note: For required torque values refer to the torque table in Section 10.0.
Apply a thin film of a silicone type lubricant to the inner periphery of the V-Ring (Item *10).
Slide the v-ring over the shaft. Refer to the bearing frame assembly drawing in Section 10.0
for the proper fitted width.
For bearing frame assemblies that are not equipped with a bearing isolator, install the V-Ring
(Item *12) as follows, otherwise proceed to Section 8.4.
Apply a thin film of a silicone type lubricant to the inner periphery of the v-ring. Slide the v-ring
over the shaft. Refer to the bearing frame assembly drawing in Section 10.0 for the proper
fitted width.
If your pump is not equipped with a bearing isolator proceed to Section 9.0
8.4 BEARING ISOLATOR ASSEMBLY
Install the O-Ring (Item *20) into the o-ring groove on the outside diameter of the Stator (Item
325). Install the O-Ring (Item *21) into the o-ring groove on the inside diameter of the Rotor
(Item 325).
Apply a silicone type lubricant to the o-ring and pilot diameter of the stator. Slide the stator
over the shaft and press it into the socket in the radial bearing housing. Make sure that the o-
ring is not damaged and the flange face of the stator is flush with the face of the radial bearing
housing.
Apply a silicone type lubricant to the o-ring and inside diameter of the rotor. Slide the rotor
over the shaft with the grooved face toward the stator until it is flush with the stator. Make sure
that the o-ring is not damaged during the installation process.

TITLE: DEC INSTALLATION, OPERATION AND DOCUMENT NO: TED-056 REV. NO: 2 SHEET 26 OF 39
MAINTENANCE MANUAL
PREPARED BY: KSH DATE: 1 MAY 1997
APPROVED BY: DATE: SUPERSEDES: 1
EFFECTIVE: 24 APR 2001 PUMP SERIAL NUMBER:
9.0 WET END ASSEMBLY
Inspect and inventory all the parts before you begin assembly. Clean
the parts and remove any burrs as required. Assembly of the wet end
should be performed in a clean, dust free area. Read these
instructions and drawings before you begin.
9.1 BASEPLATE INSTALLATION
Refer to the top view in Figure 9.1.1 for proper orientation.
Put the Bearing Housing Assembly (Item 300) on the floor and
carefully support the shaft end of the housing such that the
shaft is approximately level.
CAUTION : THE SHAFT SHOULD BE WRAPPED IN CLOTH IN ORDER TO

PROTECT IT DURING BASEPLATE AND COLUMN INSTALLATION.
Install two lifting shackles in the foundation bolt holes along

the long side of the Baseplate (Item 401). Using a chain or
other suitable lifting sling placed through the lifting eyes,
lift the baseplate.
CAUTION : THE BASEPLATE IS HEAVY, KEEP HANDS AND FEET CLEAR

FROM
UNDERNEATH.
Taking care not to damage the shaft, slide the baseplate over
the shaft, until the mounting holes in the baseplate line up
with those in the bearing housing. Ensure that the holes to
mount the discharge pipe cover plate will be facing up when the
pump is installed.
Apply a small amount of “Never-seez” or similar compound to the

Hex Head Cap Screws (Item *25). Fasten the baseplate to the
bearing housing using the hex head cap screws, Nuts (Item *27)
2 3379 SH 30 & 35 - GASKET (ITEM *34) WAS O-RING, GAP 0.5mm WAS 0.25mm DL DL 24/04/01
MAINTENANCE MANUAL
and Lock Washers (Item *26) and tighten in a criss-cross fashion

to required torque value.
Note: For required torque values refer to the torque table in

Section 10.0.
MAINTENANCE MANUAL
9.2 COLUMN AND IMPELLER INSTALLATION
Wrap a chain or other suitable lifting sling around the Column

(Item 501) ensure that it will lift in a level fashion.
Carefully lift the column and slide it over the shaft and the
outside diameter of the radial bearing housing, until the column
is flush with the bearing housing inside the profile cut in the
baseplate. The face of the column should be slightly recessed
from the bottom of the baseplate. Ensure that the holes in the
column are aligned with the holes in the bearing housing.

Hex Head Cap Screws (Item *28). Fasten the column to the
bearing housing using the hex head cap screws, Nuts (Item *30)
and Lock Washers (Item *29) and tighten in a criss-cross fashion
to required torque value.

Section 10.0.
Slide the Gasket (Item *31) onto the shaft and into position on
the shaft shoulder. Slide the Delivery Cover (Item 104) over
the shaft and seat it against the bottom of the column. It will
be clamped into place by the installation of the casing.
Install the Impeller Key (Item *32).

keyed diameter of the shaft, the impeller key, and the inside
diameter of the Impeller (Item 202). Slide the impeller over
the shaft and the impeller key until it is seated against the
shaft shoulder.
MAINTENANCE MANUAL
Slide the Impeller Collar (Item 204) over the shaft, Apply
a small amount of “Never-seez” or similar compound to the
shaft threads and tighten the assembly using the Impeller
Nut (Item 206).
MAINTENANCE MANUAL
9.2.1 (ctd)
Measure the impeller clearance ‘G’ to ensure that it is

between 1 and 2 mm. To adjust the gap add or remove Shims
(Item *14) in the position shown in Figure 8.3.3.
Insert the O-Ring (Item *33) into the o-ring groove of the
Impeller Lock Fitting (Item 215). Apply a thin film of a
silicone type lubricant to the outside diameter of the
impeller lock fitting and insert it into the impeller bore.
Apply a thin film of a silicone type lubricant to the
gasket (Item *34) and slide it over the Socket Head Cap
Screw (Item *35). Apply a small amount of “Never-seez” or
similar compound to the socket head cap screw and use it to
tighten the assembly.
Note: For required torque values refer to the torque table

in Section 10.0.

9.2.3 CUTTER OPTION
Insert the O-Ring (Item *33) into the o-ring groove on the
Impeller Nut (Item 206). Apply a small amount of “Never-
seez” to the shaft threads and use the impeller nut to
tighten the assembly. Slide the O-Ring (Item *34) over the
end of the shaft, and position it in the groove of the
impeller lock nut.
MAINTENANCE MANUAL

MAINTENANCE MANUAL
9.3 CASING AND SUCTION HARDWARE INSTALLATION

Studs (Items *36) and install them into the tapped holes in the
Casing (Item 101) using a stud driver or other suitable tool.
Slide the O-Ring (Item *37) over the impeller, and seat it
against the shoulder diameter of the delivery cover. Lift the
casing using a chain or other suitable lifting sling placed
around the discharge flange.
CAUTION : THE CASING IS HEAVY, KEEP HANDS AND FEET CLEAR FROM
UNDERNEATH.
Position the casing against the bottom of the column such that
the studs are aligned with the holes in the column. Also ensure
that the discharge flange is aligned with the profile cut in the
baseplate for the discharge pipe. Apply a small amount of
“Never-seez” or similar compound to the studs. Fasten the casing
to the column using the Nuts (Item *38) and Lock Washers (Item
*39) and tighten in a criss-cross fashion to required torque
value.

Section 10.0.
Apply a small amount of “Never-seez” or similar compound to

the Socket Head Cap Screws (Item *40) and fasten the
Strainer (Item 801) to the casing using the socket head cap
screws and Lock Washers (Item *41) and tighten in a criss-
cross fashion to required torque value.
MAINTENANCE MANUAL

in Section 10.0.

the shaft threads. Screw the Agitator (Item 207) onto the
shaft and use a brass punch and a hammer to ensure that the
agitator is tight.
Place the Gasket (Item *40) between the casing and the
Suction Piece (Item 811). This gasket is not required if
your pump is equipped with a rubberized suction piece.
the Hex Head Cap Screws (Item *43) and fasten the suction
piece to the casing using the hex head cap screws, Nuts
(Item *42) and Lock Washers (Item *41) and tighten in a
criss-cross fashion to required torque value. For the DEC
61-50 the hex head cap screws are not required, as studs
are mounted in the casing.

in Section 10.0.
9.3.3 CUTTER OPTION

the Studs (Items *41) and install them into the tapped
holes in the casing using a stud driver or other suitable
tool. Slide the Stationary Cutter (Item 220) over the
studs. Apply a small amount of “Never-seez” or similar
compound to the studs and fasten the Stand (Item 805) to
the casing using the Nuts (Item *43) and Lock Washers (Item
*42) and snug the fasteners such that there is no play in
the assembly, but do not torque the nuts.
MAINTENANCE MANUAL

the shaft threads. Screw the Axial Cutter (Item 219) onto
the shaft and use a brass punch and a hammer to ensure that
the cutter is tight.
Measure the gap ‘G2’ between the face of the stationary

cutter and the axial cutter as shown in Figure 9.3.3.2.
Loosen the Nuts (Item *42) and add Shims (Item *40) such
that the measured gap is 0.5 mm (0.020 in) and re-tighten
the nuts in a criss-cross fashion to required torque value.

in Section 10.0.
MAINTENANCE MANUAL
9.4 DISCHARGE PIPE INSTALLATION
Insert the Gasket (Item *46) between the Discharge Elbow (Item
601) and the casing.

Hex Head Cap Screws (Item *47). Use the hex head cap screws,
Nuts (Item *44) and Lock Washers (Item *45) to fasten the
discharge elbow to the casing and tighten in a criss-cross
fashion to required torque values. The hex head cap screws are
not required for the DEC 61-50 as studs are installed in the
casing.

Section 10.0.
Insert the Gasket (Item *50) between the discharge elbow and the
Discharge Pipe (Item 611).

Hex Head Cap Screws (Item *51). Use the hex head cap screws,
Nuts (Item *49) and Lock Washers (Item *48) to fasten the
discharge elbow to the discharge pipe and tighten in a criss-
cross fashion to required torque value. Ensure that the
discharge pipe fits properly in the profile cut in the
baseplate.

Section 10.0.

Hex Socket Countersunk Head Screws (Item *52) and use them to
fasten the Coverplate (Item 404) onto the baseplate.

Section 10.0.
2853 Douglas Road
Burnaby, BC V5C 6H2
Tel: (604) 298-1213 Fax: (604) 298-1224
PARTS LIST - DEC82-80-5E-72

Ref. Dwg. No. D2126 Rev.7, D5415 Rev.0, D5144 Rev.1 Serial No. 19757 TPSD-030 Rev.0
Please use the part number when ordering. Effective: APR.4 , 2003
REF # PART # DESCRIPTION QTY
999 ASSEMBLY, PUMP COMPLETE 1
022.1 TOYO SUPPLIED DRIVER SHEAVE 1

022.2 TOYO SUPPLIED DRIVEN SHEAVE 1
022.3 TOYO SUPPLIED BELT 2
022.4 TOYO SUPPLIED DRIVER BUSHING 1
022.5 TOYO SUPPLIED DRIVEN BUSHING 1
499 ASSEMBLY, MOTOR MOUNTING 1

040.1 040 405 00 01390 SCREW, HEX. HD. CAP 3
040.2 040 057 00 01437 WASHER, FLAT 3
040.3 040 432 00 01392 WASHER, LOCK 3
040.4 040 428 00 01391 NUT, HEX. 3
040.5 040 405 00 01686 SCREW, HEX. HD. CAP 4
040.6 040 432 00 02046 WASHER, LOCK 4
040.7 040 428 00 01403 NUT, HEX. 4
040.8 040 405 00 01703 SCREW, HEX. HD. CAP 2
040.9 040 405 00 01706 SCREW, HEX. HD. CAP 2
040.10 040 432 00 01395 WASHER, LOCK 8
040.11 040 428 00 01394 NUT, HEX. 8
411 411 057 51 06809 PLATE, MOTOR MOUNTING 1
443 443 200 51 06701 ASSEMBLY, V-BELT GUARD 1
447 447 067 51 05242 COVER, GUARD 1
444 444 057 51 00034 BRACKET, GUARD, V-BELT 2
448 448 200 00 04809 ROD, TENSION 2
900 ASSEMBLY, PUMP 1

* 020.1 020 052 00 03097 KEY, DRIVE 1
* 020.2 020 052 00 03381 KEY, IMPELLER 1
040.1 040 405 00 01390 SCREW, HEX. HEAD CAP 6
040.2 040 405 00 01892 STUD 12
040.3 040 405 00 01583 SCREW, HEX. HEAD, CAP 8
040.4 040 432 00 01389 WASHER, LOCK 20
040.5 040 428 00 01388 NUT, HEXAGON 20
040.6 040 405 00 01458 SCREW, SKT. HEAD, CAP 4
040.7 040 432 00 01395 WASHER, LOCK 4
040.8 040 428 00 01782 NUT, HEXAGON 1
040.9 040 057 00 01437 WASHER, FLAT 6
** 060.1 060 124 00 09115 GASKET 2
** 060.2 060 125 00 02661 GASKET 1
** 062 062 162 00 03876 O-RING 1
* 101 101 011 02 03140 CASING, PUMP 1
** 104 104 011 02 03160 COVER, DELIVERY 1
201 201 054 02 02465 SHAFT 1
** 202 202 011 00 00364 IMPELLER 1
* 204 204 054 02 04087 SLEEVE, DISTANCE 1
** 207 207 011 12 03433 AGITATOR 1
300 ASSEMBLY, BEARING HOUSING 1

** CRITICAL SPARES
* RECOMMENDED SPARES PAGE 1
2853 Douglas Road
Burnaby, BC V5C 6H2
Tel: (604) 298-1213 Fax: (604) 298-1224
PARTS LIST - DEC82-80-5E-72

Ref. Dwg. No. D2126 Rev.7, D5415 Rev.0, D5144 Rev.1 Serial No. 19757 TPSD-030 Rev.0
Please use the part number when ordering. Effective: APR.4 , 2003
REF # PART # DESCRIPTION QTY
030.1 030 200 00 02750 FITTING, PRESSURE RELIEF 1

030.2 030 200 00 01545 FITTING, GREASE 1
030.3 030 200 00 02776 FITTING, GREASE 1
040.1 040 405 00 01586 SCREW, HEX., HEAD, CAP 4
040.2 040 432 00 01389 WASHER, LOCK 4
040.3 040 428 00 01388 NUT, HEXAGON 4
040.5 040 432 00 01395 WASHER, LOCK 4
040.6 040 428 00 01394 NUT, HEXAGON 4
040.8 040 432 00 02047 WASHER, LOCK 8
040.9 040 428 00 01779 NUT, HEXAGON 8
** 061.1 061 161 00 02646 SEAL, LIP 1
** 061.2 061 161 00 02675 SEAL, LIP 1
** 061.3 061 161 00 02665 SEAL, LIP 1
** 062.1 062 162 00 02359 O-RING 1
** 062.2 062 162 00 02364 O-RING 1
** 063.1 063 165 00 02129 V-RING 1
** 063.2 063 165 00 02121 V-RING 1
** 072 072 200 00 00705 BEARING, ANGULAR CONTACT BALL 2
** 073 073 200 00 00710 BEARING, CYLINDRICAL ROLLER 1
* 079.1 079 200 00 02213 WASHER, LOCK 1
* 079.2 079 200 00 02199 NUT, LOCK 1
* 090.1 090 132 51 02764 KIT, SHIM 1
* 090.2 090 080 51 02760 KIT, SHIM 1
301 301 057 52 02937 HOUSING, RADIAL BEARING 1
303 303 067 51 02751 RETAINER, GREASE 1
311 311 004 51 02756 HOUSING, THRUST BEARING 1
315 315 057 51 02758 END COVER, THRUST BEARING 1
331 331 200 51 02754 HOUSING, BEARING 1
401 401 057 02 05718 BASEPLATE 1
404 404 057 02 09013 COVERPLATE 2
501 501 200 02 02461 COLUMN, SUPPORT 1
601 601 011 00 02631 ELBOW, DISCHARGE 1
611 611 200 02 09003 PIPE, DISCHARGE 1
801 801 200 02 04094 STRAINER 1
830 ASSEMBLY, JET RING 1

080 080 060 00 02237 COUPLING, PIPE 1
404 404 057 02 03864 COVER PLATE 1
831 831 200 02 08162 JET RING 1
832 832 200 02 08179 PIPE, DELIVERY 1
** CRITICAL SPARES
* RECOMMENDED SPARES PAGE 2

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TOYO PUMPS NORTH AMERICA CORPORATION

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

SECTION 2.0 TECHNICAL DATA SHEET

2.1 CUSTOMER FILL IN DATA SHEET

SECTION 3.0 WARRANTIES

SECTION 4.0 SAFETY

SECTION 5.0 INSTALLATION

5.1 CHECK UPON ARRIVAL

5.2.1 NEW PUMP AND EQUIPMENT STORAGE

5.6 SUCTION AND DISCHARGE PIPING

5.7 POWER SUPPLY

SECTION 6.0 OPERATION

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

TABLE OF CONTENTS (ctd)

7.1 INSPECTION AND ADJUSTMENT FOR WEAR

7.3 TROUBLE SHOOTING

SECTION 8.0 BEARING FRAME ASSEMBLY

8.1 SHAFT PRE-ASSEMBLY

SECTION 9.0 WET END ASSEMBLY

9.1 BASEPLATE INSTALLATION

9.2.1 AGITATOR OPTION

9.3 CASING AND SUCTION HARDWARE INSTALLATION

9.3.1 AGITATOR OPTION

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

TABLE OF CONTENTS (ctd)

SECTION 10.0 APPENDIX

10.1 BOLT TORQUE TABLE

10.4.1 PUMP PERFORMANCE CURVE

10.5 BEARING FRAME ASSEMBLY DRAWING

10.8 PARTS LIST

10.9 AUXILIARY EQUIPMENT

10.9.1 ELECTRIC MOTOR INFORMATION

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

Drawing B____: Shaft Pre-Assembly................................................................................................. 17

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

NOT ALL PUMPS ARE OF STANDARD CONFIGURATION

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

2.0 TECHNICAL DATA SHEET

PUMP SPEED (RPM) :

FOR COMPLETE PUMP DATA SHEET SEE SECTION 10.0

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

2.1 CUSTOMER FILL IN DATA SHEET

START-UP OPERATING CONDITIONS

FLOW (USGPM) NORMAL :

DISCHARGE PRESSURE (PSI) :

MAX. PARTICLE SIZE (IN.) :

START-UP PUMP DATA

PUMP SPEED (RPM) :

POWER DRAW (AMPS) :

OIL TEMPERATURE (°F) :

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

5.1 CHECK UPON ARRIVAL

5.2.1 NEW PUMP AND EQUIPMENT STORAGE

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

ROTATE ONCE A MONTH

5.2.2 USED PUMP STORAGE

5.2.3 SPARE PARTS STORAGE

See Section 2.0, TECHNICAL DATA SHEET for weight information.

REV ECN CHANGE DESCRIPTION BY APPV’D DATE

5.6 DISCHARGE PIPING

5.7 POWER SUPPLY

REV ECN CHANGE DESCRIPTION BY APPV’D DATE