Sulzer J 205, Workshop Manual

2

Contents

1  

General

 ...............................................................................................................................................4

1.1  

Service intervals  ..................................................................................................................................4

1.2  

Repair kits  ...........................................................................................................................................4

1.3  

Tools  ....................................................................................................................................................4

1.4  

Complete pump overhaul   ...................................................................................................................5

1.5  

Cleaning of pump before service  ........................................................................................................5

1.6  

Recycling in case of scrapping the pumps ...........................................................................................5

2  

Electrical check  .................................................................................................................................6

2.1  

Pump start and cable check  ................................................................................................................6

2.2  

Dismantling cover  ................................................................................................................................6

2.3  

Insulation test  ......................................................................................................................................7

2.4  

Thermal contacts  .................................................................................................................................7

3  

Oil / Motor check  ...............................................................................................................................8

3.1  

Oil check  .............................................................................................................................................8

3.2  

Motor check J 205  ...............................................................................................................................8

4  

Impeller clearance check  ..................................................................................................................9

4.1  

Dismantling base plate and strainer  ....................................................................................................9

4.2  

Clearance measure  .............................................................................................................................9

5  

Change of impeller / Check of diffuser and wear ring

 ..................................................................10

6  

Change of mechanical seal unit on J 205, J 405 / Mechanical seal on J 604

 .............................11

7  

Complete pump overhaul / Dismantling

 ........................................................................................12

7.1  

Electrical supply leads  .......................................................................................................................12

7.2  

Discharge connection .........................................................................................................................12

7.3  

Cooling jacket  ....................................................................................................................................12

7.4  

Motor housing  ...................................................................................................................................13

7.5  

Rotor + shaft and ball bearings   ........................................................................................................13

7.6  

Wear plate on J 205 and J 405 ..........................................................................................................14

8  

Exchange of stator 

 ..........................................................................................................................14

8.1  

Removal of stator  ..............................................................................................................................14

8.2  

Mounting of new stator  ......................................................................................................................15

8.3  

Mounting of terminal plate / Upper bearing bracket  ..........................................................................16

9  

Complete pump overhaul / Assembly 

 ...........................................................................................17

9.1  

General  .............................................................................................................................................17

9.2  

Terminal blocks & contactor  ..............................................................................................................17

9.3  

Wear plate on J 205 and J 405  .........................................................................................................17

9.4  

Ball bearings and rotor + shaft mounted on oil casing  ......................................................................17

9.5  

Motor housing & rotor unit with oil casing ..........................................................................................18

9.6  

Mechanical seals on J 205 - J 604 and upper/lower oil casing on J 604 ...........................................19

9.7  

Cooling jacket J 604 ...........................................................................................................................19

9.8  

Impeller, diffuser & wear ring 

 .............................................................................................................20

9.9  

Leakage test of mechanical seals  .....................................................................................................20

9.10  

Refilling of oil 

 .....................................................................................................................................20

9.11  

Cooling jacket J 205 and J 405  .........................................................................................................21

9.12  

Strainer, base plate and handle  ........................................................................................................21