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Instruction Manual
Rotary Lobe Pumps - OptiLobe

TD 246-034

ESE00528EN1

2007-09

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EC Declaration of Incorporation

The designating company

Alfa Laval Eastbourne, Alfa Laval Ltd

Company Name

Birch Road, Eastbourne, East Sussex BN23 6PQ

Address

+44 (0) 1323 412555

Phone No.

Herewith declares that:

- Rotary Lobe Pump within OptiLobe range
is in conformity with the provisions of the Machinery Directive 2006/42/EC and with the national implementing legalization
and NOT to be put into service until machinery which this product is to be part of is declared to confirm with Machinery
Directive 2006/42/EC

and furthermore declares that:
the following (parts/clauses of) applicable directives have been used
-
-

Directive 2006/95/EC on low voltage

Electro Magnetic Compatibility Directive 2004/108/EC

the following (parts/clauses of) harmonized standards have been applied

-
-
-
-
-
-
-
-
-
-
-
-
-

EN 809
EN 294
EN 349
EN 563
EN 953
EN 1037
EN 12162
EN 12639
EN 14343
EN 60529
EN 60034
EN 60204
ISO 9001

A technical construction file for this machinery is retained at the above address.

Signed

(Authorised Person)

Date

Name

Position

Bjarne Sndergaard

Vice President R&D Equipment Division

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EC Declaration of Conformity

The designating company

Alfa Laval Eastbourne, Alfa Laval Ltd

Company Name

Birch Road, Eastbourne, East Sussex BN23 6PQ

Address

+44 (0) 1323 412555

Phone No.

Herewith declares that:

- Rotary Lobe Pump within OptiLope range - motorized
is in conformity with the provisions of the Machinery Directive 2006/42/EC and with the national implementing legalization.

and furthermore declares that:
the following (parts/clauses of) applicable directives have been used
-
Directive 2006/95/EC on low voltage
-
Electro Magnetic Compatibility Directive 2004/108/EC
the following (parts/clauses of) harmonized standards have been applied
-
-
-
-
-
-
-
-
-
-
-
-
-

EN 809
EN 294
EN 349
EN 563
EN 953
EN 1037
EN 12162
EN 12639
EN 14343
EN 60529
EN 60034
EN 60204
ISO 9001

A technical construction file for this machinery is retained at the above address.

Signed

(Authorised Person)

Date

Name

Position

Bjarne Sndergaard

Vice President R&D Equipment Division

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EC Declaration of Conformity for Safety Components

The designating company

Alfa Laval Eastbourne, Alfa Laval Ltd

Company Name

Birch Road, Eastbourne, East Sussex BN23 6PQ

Address

+44 (0) 1323 412555

Phone No.

Herewith declares that safety components:

-
Gland guards
-
Coupling guards
are in conformity with the provisions of the Machinery Directive 2006/42/EC and with the national implementing
legalisation.
and furthermore declares that:
the following (parts/clauses of) harmonized standards have been applied:
-
-
-

EN 809
EN 294
EN 60529

A technical construction file for this machinery is retained at the above address.

Signed

(Authorised Person)

Date

Name

Position

Bjarne Sndergaard

Vice President R&D Equipment Division

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Table of contents

The information contained herein is correct at the time of issue but may be subject to change without prior notice.

1. General description.............................................................................. 10
2. Safety.................................................................................................... 11
2.1 Important information....................................................................... 11
2.2 Warning signs.................................................................................. 11
2.3 Safety precautions........................................................................... 12
3. Installation............................................................................................ 13
3.1 Unpacking, Handling and Storage.................................................... 13
3.2 System design and installation......................................................... 14
3.3 Flushing seal arrangement and pre-start up checks......................... 18
4. Maintenance......................................................................................... 19
4.1 Cleaning in place (CIP)..................................................................... 19
4.2 Maintenance schedule..................................................................... 20
4.3 Disassembly.................................................................................... 21
4.4 Assembly......................................................................................... 24
4.5 Primary seals removal and fitting...................................................... 29
4.6 Troubleshooting............................................................................... 31
5. Technical data....................................................................................... 32
5.1 Technical data.................................................................................. 32
5.2 Pumphead Clearance information.................................................... 33
6. Parts list................................................................................................ 34
6.1 OptiLobe Pump Range.................................................................... 34

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1. General description

1.1 General description

The Alfa Laval OptiLobe range of pumps is of conventional rotary lobe pump design with the positive displacement being
provided by non-contacting, contra rotating tri-lobe rotors
within a fully swept pump chamber.

Drawing shows only mounted unit

Drive unit

The OptiLobe pump range has a universal gearbox design

which gives the flexibility of mounting pumps with the inlet and
outlet ports in either a vertical or horizontal plane by changing
the foot position.
Handling from low to high viscosity pumped media, the pumps
characteristic smooth, low shear pumping action is ideal in
application areas such as Brewing, Dairy, Food industries, and
is suitable for CIP (Cleaning In Place).

Gearbox

Ports

Rotorcase
cover

Rotorcase

Coupling guard
(encloses coupling)
TD 246-035

Pump duty conditions

The pump should only be used for the duty for which it has been specified. The operating pressure, speed and temperature
limits have been selected at the time of order and MUST NOT be exceeded. These details are stated on the original order
documentation and if not available may be obtained from your supplier quoting pump model and serial number.

Noise levels
Under certain operating conditions pumps and/or drives and/or the systems within which they are installed can produce sound
pressure levels in excess of 80 dB[A]. When necessary, protection against noise should be taken.

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2. Safety

2.1 Important information

2.2 Warning signs

Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.

Always read the manual before using the pump!

WARNING!
Indicates that special procedures must be followed to avoid severe personal injury.
CAUTION!
Indicates that special procedures must be followed to avoid damage to the pump.
NOTE!
Indicates important information to simplify or clarify practices.

General warning:

Dangerous electrical voltage:

Caustic agents:

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2.3 Safety precautions

Pay special attention to the instructions below so that severe personal injury or damage to the pump are avoided.

Installation
- Always observe the technical data (see chapter 5).
- Never start in the wrong direction of rotation with liquid in the pump.
- Never put your hands or fingers inside the port connections or anywhere close to rotating
shafts.
The pump must be electrically connected by authorised personnel (see the motor instructions
supplied with the drive unit).

Operation
- Always observe the technical data (see chapter 5).
- Never touch the pump or the pipelines when pumping hot liquids or when sterilising.
- Never stand on the pump or pipelines.
- Never run the pump with either the suction side or the pressure side blocked.
- Never put your hands or fingers inside the port connections or anywhere close to rotating
parts.
- Never run the pump unless fully assembled and all guards are securely fitted, i.e. pump
head must not be removed from gearcase.
Only handle toxic and acidic liquids in accordance with the manufacturers instructions and
recommendations.

Maintenance
- Always observe the technical data (see chapter 5).
- The pump must never be serviced when hot.
- The pump and the pipelines must never be pressurised when the pump is being serviced.
- Never put your hands or fingers inside the port connections or anywhere close to rotating
parts.
- Installation and operation of the pump must always comply with health and safety
regulations. Any hazardous and/or hot, drained or leaked, liquid shall be disposed in
compliance with health and safety regulations.
If requested at the time of order, the equipment can be supplied with means of safe
removal of any hazardous and/or hot, drained or leaked liquid.
- Always disconnect the power supply when the pump is being serviced.

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2. Safety

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3. Installation

3.1 Unpacking, Handling and Storage

Step 1
Refer to the pump weights guide (chapter 5) before selecting and using any lifting gear. The drawings show how the pump
should be lifted.
Ensure that lifting equipment is correctly rated and used within these limits.
Pump with drive unit

TD 246-041

Bareshaft pump

TD 246-042

TD 246-043

TD 246-044

Step 2
On receipt always:
- Check the delivery note against the goods received.
- If motorised, check that the drive instructions are available.
- Be careful not to discard any manuals that may be enclosed with the packaging.
- Inspect the packing for signs of damage in transit.
- Carefully remove the packing away from the pump.
- Inspect the pump for any visible signs of damage.
- Clean away the packing from the pump port connections.
- Report any damage immediately to the carrier.

Step 3
After receipt and inspection, if the pump is not to be installed immediately, the pump should be repacked and placed in suitable
storage. The following points should be noted:
-
-
-

-
-

Plastic or gasket type port covers should be left in place.

Pumps received wrapped with corrosion inhibiting treatment material should have wrapping replaced.
A clean, dry storage location free from vibration should be selected. If a moist or dusty atmosphere is used for storage,
further protect the pump or unit with a suitable cover.
Rotate the pump/pump unit by hand weekly, to prevent bearing damage.
All associated ancillary equipment should be treated similarly.

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3. Installation

3.2 System design and installation

To ensure optimum operation it is important that any pump unit is installed correctly. When designing a pumping system the
following should be taken into consideration.

Design:
- Confirm the Net Positive Suction Head (NPSH) available from
the system exceeds the NPSH required by the pump, as this
is crucial for ensuring the smooth operation of the pump and
preventing cavitation.
- Avoid suction lifts and manifold/common suction lines for
two pumps running in parallel, as this may cause vibration
or cavitation.
- Protect the pump against blockage from hard solid
objects e.g. nuts, bolts welding slag etc. Also protect the
pump from accidental operation against a closed valve by
using relief valves, pressure switches or current limiting
devices.
- Fit suction and discharge monitor points for diagnostic
purposes.
- Fit valves, if two pumps are to be used on manifold/common
discharge lines.
- Make the necessary piping arrangements if flushing is
required for the seal.
- Allow at least 1 m for pump access/maintenance all around
the pump.
- Do not subject rotary lobe pumps to rapid temperature
changes, as pump seizure can result from thermal shock.

Discharge line

Plan view
Suction line
Manifold suction/Common Line

Pipework:
The pump must not be used to support piping. All inlet and outlet piping on the pump unit must be independently
supported. Failure to observe this may distort
the pump head components or pump assembly and cause serious permanent damage

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3. Installation

3.2 System design and installation

Direction of flow:
The direction of flow is dictated by the direction of rotation of the drive shaft. Reversing the direction of rotation will reverse the
flow direction.

Inlet

Outlet

Inlet

Outlet

Inlet

Outlet

TD 246-014

Inlet

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3. Installation

3.2 System design and installation

Pump Lubrication:
The pump will be supplied filled with grease. It is recommended to change the grease every 20000 hours of pump operation.
When changing the grease one of the recommended greases listed below must be used:
Aralube MFL 00
BP Energrease PR-EP00
Klubersynth UH 1 14-1600
Mobilux EP 004

Baseplate Foundations
Pumps when supplied with a drive unit are normally mounted on a baseplate. Our standard baseplates have pre-drilled
fixing holes to accept base retaining bolts. To provide a permanent rigid support for securing the pump unit, a foundation is
required which will also absorb vibration, strain or shock on the pumping unit. Methods of anchoring the baseplate to the
foundation are varied, they can be studs embedded in the concrete either at the pouring stage as shown below, or by use of
epoxy type grouts. Alternatively mechanical fixings can be used.
The foundation should be appox. 150 mm longer and wider than the baseplate. The depth of the foundation should be proportional to the size of the complete pump unit. For example, a large pump unit foundation depth should be at least 20 times
the diameter of the foundation bolts.
Waste put around bolt
before pouring concrete

Foundation surface left

through to anchor ground

D
10D
One D
Minimum
One-half D
Minimum

Sleeve
3D
Lug welded to
bolt head
4D

The drawing above shows two typical methods for foundation bolt retaining. The sleeve allows for slight lateral movement
of the bolts after the foundation is poured. Rag or waste paper can be used to prevent the concrete from entering the sleeve
while the foundation is poured. A minimum of 14 days us normally required to allow the curing of the concrete prior to pump
unit installation.

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3.2 System design and installation

3. Installation

Coupling alignment:
Before the pump unit is installed it is important to ensure that the mounting surface is flat to avoid distortion of the baseplate,
which may cause pump/motor shaft misalignment and pump/motor unit damage.

Parrallel misalignment

Angular misalignment

TD 246-047

Once the baseplate has been secured, the pump shaft to motor shaft coupling alignment should be checked and adjusted as
necessary. This is achieved by checking the maximum angular and parallel allowable misalignments for the couplings as stated
by the coupling manufacturer.

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3. Installation

3.3 Flushing seal arrangement and pre-start up checks

Step 1
A flushed seal arrangement is fitted in order to cool or clean the seal area.
It is important that:
- The flush is correctly connected (see below).
- A compatible flushing fluid is used and supplied at the correct pressure and flow rate (see step 5).
- The flush is turned on at the same time/prior to starting the pump, and turned off at the same time/after stopping the
pump.

Step 2
Connecting the flush
The following equipment is strongly recommended when using a flushing system:
- Control valve and pressure gauge, to enable the correct flushing pressure to be obtained and monitored.
- Isolation valve and check valve, so that the flush can be turned off, and to stop any unwanted substances flowing in
the wrong direction.
- A method of visibly indicating flushing fluid flow.

Flush outlet

Step 3
Flushing arrangements in principle
Flush outlet

Link
pipe

Flush intlet

TD 246-049

TD 246-048

Serial piping

Flush inlet
Parallel piping

Step 4
Flushing fluid
The choice of flushing fluid is dependent upon the fluid being pumped and duty conditions i.e. pressure and temperature. Usually
water is used for cooling or flushing water soluble products. For single flushed mechanical seal arrangements the temperature
of flush media should never allowed to exceed the maximum temperature of the pumped media. For advice on selecting a
suitable flushing fluid please contact pump supplier.

Step 5
Flushing pressure and flow rate
Single flushed mechanical seal 0.5 bar (7 psi) maximum. Any further increase in pressure will result in lip seal failure.
The flushing flow rate must be adequate to ensure that the temperature limitation of the seals is not exceeded. Contact your
pump supplier for further information on the recommended flow.
Minimum flow rate required per shaft seal is 30 l/hr
Step 6
Pre-start up checks
- Check the pipework system has been purged to remove debris.
- Check all obstructions have been removed from pipework and pump.
- Check pump connections and pipework joints are tight.
- Check lubrication levels are correct.
- Check seal flushing is connected if applicable.
- Check all safety guards are in place.
- Check that inlet and outlet valves are open.
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4. Maintenance

4.1 Cleaning in place (CIP)

The pump can be manually cleaned or cleaned in place (CIP). The following is an example of a typical CIP procedure. However
specific advice for each application should be sought from the pump supplier.
Typical CIP procedure
1. Flush through the system with cold water or bore water (6C) (43F).
2. Run hot caustic soda (70-80C) (158-176F) at 2.5% dilution through the system for 20-30 minutes.
3. Final flush through with cold water again.

Warnings
-
-

-

Never touch the pump or the pipelines as they can be extremely hot!
Do not subject the pump to rapid temperature changes during CIP procedures, as pump
seizure can result from thermal shock. A suitable by-pass is recommended.
Always rinse well with clean water after using a cleaning agent.

- Always use rubber gloves and protective goggles when handling caustic agents.
- Always store/discharge cleaning agents in accordance with current rules/directives.

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4. Maintenance

4.2 Maintenance schedule

It is advisable to install pressure gauges on both sides of the pump so that any problems within the pump/pipework can be
monitored.
Maintenance schedule
Your weekly schedule should include:
- Checking the seals for leakage.
- Checking the lip seals for leakage.
- Check pumping pressures.
In certain operational circumstances the pump will pose a thermal hazard and as such should not be touched during operation.
After shutdown the pump unit should be allowed time to cool.

Recommended Spare Parts

The table shows recommended spare parts that should be
retained within your maintenance schedule.

Part description

Quantity

O-ring rotorcase cover

O-ring rotor sealing shaft end

O-ring rotor sealing rotor retainer end

Primary seals

Rotor nut O-ring Seal Replacement Interval

It is recommended that the rotor nut O-ring seal is replaced every 12 months to maintain a bacteria tight seal.
Rotor Nut Seal Inspection
Periodically inspect the rotor nut O-ring seal for any discoloration, nicks, or cracks. If any of the defects above are
noticed, the O-ring seal must be replaced. Inspection and replacement refer to the seal replacement procedure below.
Seal Replacement Procedure
1. Remove rotor case cover (see 4.3, step 1).
2. Undo rotor nuts and ensure components are dry before servicing.
3. With a penlight, inspect rotor nut blind tapped hole for contamination. If soiled, refer to cleaning procedure below.
4. Remove and discard rotor nut O-ring seal.
5. Fit new rotor nut O-ring seal.
6. Fit rotor nut and use a torque wrench to tighten to correct torque value (see table 5.1.3).
7. Fit the rotor case cover.
Cleaning Procedure for Soiled Rotor Nut Tapped Hole
1. Remove rotor nut from the shaft.
2. Submerge and soak nut for 5 minutes in COP tank with 2% caustic wash.
3. Scrub the hole with internal thread vigorously by plunging a clean sanitary bristle pipe brush in and out of the hole for
two minutes while submerged.
4. Soak nut in acid sanitizer for 5 minutes, and then scrub the hole again with the pipe brush for two minutes.
5. Rinse well with clean water and blow-dry blind tapped hole with clean air.
6. Swab test the inside of the tapped hole to determine cleanliness.
7. Should the swab test fail, repeat steps 2 thru 6 above until swab test is passed.
Should swab testing continue to fail, or time is of the essence, install a new rotor nut.

TD 246-051

TD 246-050

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4. Maintenance

4.3 Disassembly

Step 1
Before disassembling the pump refer to safety
precautions. See exploded view drawings (chapter 6).
Removing rotorcase cover
1. Remove rotorcase cover screws (10) and cover (12).

TD 246-001

Step 2
Removing rotors
1. Insert a plastic/wooden block between the two rotors (17)
to stop them turning.
2. Remove rotor nuts (22), rotor nut O-rings (20) and rotors.
3. Remove the rotorcase cover O-ring (11) and spline sealing
O-rings (18) if these are to be replaced.
Plastic or
wooden block
TD 246-002

TD 246-003

Step 3
Removing primary seal components
Please see section 4.5 for seal removal.

Step 4
Removing rotorcase
1. Remove the rotorcase retention screws (3).
2. Tap both sides of the rotorcase (9) with a soft hammer.
3. Take care not to allow the rotorcase to drop onto the
shafts during the removal process.

TD 246-068

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4. Maintenance

4.3 Disassembly

Step 5
Removing canister
1. Place a tray under the canister (5) to collect the waste
lubricant.
2. Remove the four canister retaining screws (6) and allow
lubricant to drain.
3. Remove canister from the bearing housing (1) which is
sealed with an O-ring (21). To assist in removal a
suitable lever can be used in the slots provided.
4. Remove the canister O-ring (21) if this needs to be
replaced.
TD 246-007

Step 6
Canister lip seal removal
Extract the lip seal (7) from the seal retainer. It is essential to
renew the lip seal prior to assembly.

TD 246-008

Step 7
Removing timing gears
1. Loosen the bearing nuts (30) with a C spanner by
tapping sharply.
2. Remove the torque locking assembly screws (40) in
several stages (do not fully undo each screw on the first
stage of screw removal).
3. Insert the screws into the threaded holes in the assem bly flange and gradually tighten in a crossed sequence
until the back cone is released.
4. Slide timing gears (36) off the shafts (24 and 25).
TD 246-010

TD 246-009

Step 8
Shaft assembly removal
1. Remove bearing nuts (30) with a sharp tap on a C
spanner (see also drawing shown in step 7).
2. Using a soft hammer gently tap the rear end of each
shaft to remove through the front of the bearing
housing, supporting each shaft during removal. As
the shaft is removed the bearing housing lip seal (16)
and rear bearing (26) will also be removed.
3. Remove lip seal from shaft. It is essential to renew the lip
seal prior to assembly.

TD 246-011

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4. Maintenance

4.3 Disassembly

Step 9
Bearing removal
1. Mount the shaft vertically in a press (rotor part of the
shaft down) with a tool positively located against the
front bearing inner ring with rolling elements as shown,
and apply pressure to the top of the shaft so that the
shaft moves through the bearings.
2. From bearing housing tap the outer bearing rings (front
and back) and remove shims (27). Renew bearings if
removed from the shafts for any reason.

TD 246-015

TD 246-016

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4. Maintenance

4.4 Assembly

Take care not to damage shaft surfaces, in particular where bearings and lipseals will be located
Ensure all fastenings are tightened to the torque settings as shown in Technical Data (section 5).

Step 1
Fitting bearings to shafts
1. Apply an anti-seize compound to the shaft bearing
surfaces.
2. Place each shaft vertically in a press and fit the front
bearing inner ring with rolling elements.

TD 246-064

Step 2
Fitting bearings to housing
1. Apply an anti-seize compound to the bearing bores in
the bearing housing.
2. Press or gently tap the rear bearing outer rings into the
rear bearing bores.
3. Turn the bearing housing over and place one shim (27)
of 0.10 mm thickness against the abutment shoulder of
each front bearing bore.
4. Press or gently tap the front bearing outer rings into the
front bearing bores.
TD 246-053

Step 3
Fitting shaft assemblies
1. Pass the shaft through the front of the top bearing bores (rear part of the
shaft first), so front bearing inner ring with rolling elements fits into front
bearing outer ring placed in bearing housing.
2. Hold in place and slide the rear bearing inner ring with rolling elements over the
shaft and into the rear bearing outer ring placed in bearing housing (see drawings
above).
3. Apply a locking compound to the bearing nut thread.
4. Fit the bearing nut (30) using a C spanner and tighten to remove all axial and radial
movement.
5. Rotate the shafts several times to seat the bearings and check rolling torque to the
recommended torque value as follows:
Model 22/23 is 2 - 3 lbin (0.23 - 0.34 Nm)
Model 32/33 is 4.5 - 5.5 lbin (0.51 - 0.62 Nm)
Model 42/43 is 5 - 6 lbin (0.57 - 0.68 Nm)
6. Repeat steps 1, 2, 3 & 4 for the other shaft.
Step 4
Fitting rotorcase
Fit the rotorcase (9) to the bearing housing (1) and tighten the
rotorcase retention screws (3) to the recommended torque
value.

24

TD 246-017

TD 246-018

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4. Maintenance

4.4 Assembly

Take care not to damage shaft surfaces, in particular where bearings and lipseals will be located
Ensure all fastenings are tightened to the torque settings as shown in Technical Data (section 5).

Step 5
Fitting rotors
5.1. Fit rotors (17) onto the shafts with both dimpled rotor
master lobes in the 6 - 12 oclock position for horizon
tally ported pumps or the 3 - 9 oclock position for
vertically ported pumps. It is recommended for the
rotor on the drive shaft (24) that the rotor dimple aligns
with the drive shaft keyway.

TD 246-019

5.2.
Fit rotor nuts (22) to shafts - Use a plastic/wooden block between the rotors to stop them turning and tighten the rotor nuts
(22) to the recommended torque value (see table 5.1.3).

TD 246-020

5.3.
Using feeler gauges measure the back clearance behind each
rotor lobe and rotorcase. Refer to Pumphead Clearance Information (section 5.2). If incorrect, remove rotors, rotorcase,
shafts and front bearings, and adjust shim (27) thickness to
give correct back clearance.

TD 246-054

Step 6
Fitting timing gears
1. Lightly lubricate with oil both rear shaft diameters.
2. Lightly lubricate torque locking assemblies (40) with oil
and fit to timing gears.
3. Slide timing gear assemblies (36 and 40) onto shafts.

TD 246-021

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4. Maintenance

4.4 Assembly

Take care not to damage shaft surfaces, in particular where bearings and lipseals will be located
Ensure all fastenings are tightened to the torque settings as shown in Technical Data (section 5).

Step 7
Setting timing
Tighten one torque locking assembly only to the recommended
torque figure, allowing rotation of the shaft in the other gear
for timing adjustment. Screws should be tightened gradually
in a diametrically opposite sequence.

TD 246-022

Step 8
Adjusting rotor timing
1. Turn the shaft so that the rotors are in new positions
as shown.
2. Squeeze the rotors together and using feeler gauges
check the minimum mesh clearance is within
specification. Refer to Pumphead Clearance Information
(section 5.2).
3. Tighten the other torque locking assembly to the
recommended torque figure.
4. Confirm timing is correct as described in step 8.
5. Remove rotor nuts and rotors.
TD 246-038

TD 246-037

Step 9
Fitting bearing housing lip seals
1. Lightly lubricate lip seals (16) with compatible lubricant.
2. Slide lip seals over shafts and tap into bearing bore.
Ensure lip seals are not damaged when sliding them
onto the shafts.

TD 246-024

Step 10
Fitting spline sealing O-rings
Lightly lubricate spline sealing O-rings (18) and fit over shaft
splines to locate against the rotor abutment shoulder.

TD 246-055

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4. Maintenance

4.4 Assembly

Take care not to damage shaft surfaces, in particular where bearings and lipseals will be located
Ensure all fastenings are tightened to the torque settings as shown in Technical Data (section 5).

Step 11
Fitting mechanical seals
Refer to section 4.5 for seal fitting instructions.

Step 12
Fitting rotors
1. Fit rotors onto the shafts with both dimpled rotor master
lobes in the 6 - 12 oclock position for horizontally ported
pumps or the 3 - 9 oclock position for vertically ported
pumps. For the rotor on the drive shaft the rotor dimple
should be aligned with the drive shaft keyway.
2. Lightly lubricate the rotor nuts O-rings (20) and fit to rotors.
3. Fit rotor nuts to shafts.
Use a plastic/wooden block between the rotors to stop them
turning and tighten the rotor retention nuts to the
recommended torque figure.
4. Check clearances. Refer to Pumphead Clearance
Information (section 5.2).

TD 246-025

TD 246-028

Step 13
Fitting rotorcase cover
1. Lightly smear rotorcase cover O-ring (11) with com patible lubricant and fit to rotorcase.
2. Fit rotorcase cover onto rotorcase and tighten rotorcase
cover screws (3) to the recommended torque value.

TD 426-026

Step 14
Fitting canister and lip seal
1. Lightly lubricate canister O-ring (21) and fit into
O-ring groove of bearing housing (1).
2. Fit lip seal (7) into the seal retainer that is fitted to the
canister.
3. Smear oil on the inner lip of the lip seal and carefully
slide the canister over the shaft to locate with the
bearing housing by aligning screw holes. Fit and
tighten screws (6) to the recommended torque figure.
TD 246-027

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4.4 Assembly

4. Maintenance

Take care not to damage shaft surfaces, in particular where bearings and lipseals will be located
Ensure all fastenings are tightened to the torque settings as shown in Technical Data (section 5).

Step 15
Adding lubrication
1. Remove both plastic blanking plugs on the bearing
housing to expose screws to be removed.
2. Pour the recommended grease lubricant into the tapped
hole.
3. Replace screws and plastic blanking plugs.

TD 246-039

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4. Maintenance

4.5 Primary seals removal and fitting

4.5.1 EasyFit Single mechanical seal

Mechanical seals are fragile. Take extreme care when handling.
Clean components before fitting, checking there is no
damage to sealing faces. New elastomer parts should be
fitted during assembly.
The EasyFit mechanical seal is completely front loading
without need of removing rotorcase for access or replacement. The seal setting distance is pre-set.

101
104

102
105

107
103

Int

106

or
oto

r
Int

or
oto

rca

Item

Description

101

Wave spring

102

Rotary seal ring O-ring

103

L cup seal

104

Rotary seal drive ring

105

Rotary seal ring

106

Stationary seal drive ring

107

Stationary seal ring

se

TD 246-070

Step 1
Seal removal
1. Remove rotorcase cover, rotor nuts, rotors and
gland guards.
2. Extract the rotary seal ring (105), rotary seal drive ring
(104), wave spring (101) and rotary seal ring O-ring (102)
from the rear of the rotor.
Take extreme care whilst extracting rotary seal ring.
3. Gently ease the stationary seal assembly from the
rotorcase using a suitable lever against the stationary
seal drive ring (106) extrusions reachable from the back
of the rotorcase.

Step 2
Seal fitting
1. Lightly lubricate L seal (103) and fit onto the stationary seal ring (107).
2. Fit drive ring to L cup seal ring assembly by aligning the flats on the stationary seal drive ring (106) and stationary seal ring.
3. Gently press the stationary seal ring assembly into the rotorcase bore ensuring that the anti-rotation extrusions in the
stationary seal drive ring (106) align with the slots in the rotorcase.
4. Fit wave spring (101) into the rear bore of the rotor.
5. Fit rotary seal drive ring (104) into rear bore of the rotor ensuring that the anti-rotation extrusions locate in the slots in the rotor.
6. Lightly lubricate rotary seal ring O-ring and fit into the rear bore of the rotor
7. Align the two flats on the rotary seal ring (105) with the drive flats in the drive ring and gently press the rotary seal ring into
the rear bore of the rotor, through the rotary seal ring O-ring (102).
8. Wipe clean the sealing faces with solvent and fit gland guards, rotors, rotor nuts and rotorcase cover.

29

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4. Maintenance

4.5 Primary seals removal and fitting

4.5.2 EasyFit Single Flushed mechanical seal

Mechanical seals are fragile. Take extreme care when handling.
Clean components before fitting, checking there is no
damage to sealing faces. New elastomeric parts should be
fitted during assembly.
The EasyFit mechanical seal is completely front loading
without need of removing rotorcase for access or replacement. The seal setting distance is pre-set.
Item

Description

101

Wave spring

102
103

Rotary seal ring O-ring

L cup seal

104

Rotary seal drive ring

105

Rotary seal ring

106

Stationary seal drive ring

107

Stationary seal ring

Seal housing
Seal housing stud
Seal housing nut
Lip Seal

101
104

102
105

107
103

Int

106

or
oto

111
108

Int

or
oto

109
110

rca

se
TD 246-071

108
109
110
111

Step 1
Seal removal
1. Remove rotorcase cover, rotor nuts, rotors and gland guards.
2. Extract the rotary seal ring (105), rotary seal drive ring (104), wave spring (101) and rotary seal ring O-ring (102) from the
rear of the rotor. Take extreme care whilst extracting rotary seal ring.
3. Drain seal housing (108) for any liquid and dispose drained liquid in accordance to existing legislation.
4. If only the mechanical seals are to be replaced, a suitable lever can be used to gently ease the stationary seal assembly
from the rotorcase.
If complete disassembly of the flushed seal components is necessary, remove the rotorcase complete with seal housing.
5. Undo the seal housing retention nuts.
6. Remove the seal housings and extract the lip seals from the seal housings.
7. Remove the seal housing O-ring from the rotorcase.
8. Gently ease the stationary seal assembly from the rotorcase using a suitable lever against the stationary seal drive ring
extrusions reachable from the back of the rotorcase.
Step 2
Seal fitting
1. Lightly lubricate L cup seal (103) and fit onto the stationary seal ring (107).
2. Fit stationary seal drive ring (106) to L cup seal face assembly by aligning the flats on the stationary seal drive ring and
stationary seal ring.
3. Gently press the stationary seal drive ring assembly into the rotorcase bore ensuring that the anti-rotation extrusions in
the stationary seal drive ring align with the slots in the rotorcase.
4. If the rotorcase has been removed, lightly lubricate the seal housing O-rings and fit to the rotorcase.
5. Press new lip seals into the seal housings.
6. Fit seal housings to the rotorcase and tighten the seal housing retention nuts to the recommended torque figure.
7. Refit the rotorcase to the bearing housing.
8. Fit wave spring (101) into the rear bore of the rotor.
9. Fit rotary seal drive ring (104) into rear bore of the rotor ensuring that the anti-rotation extrusions locate in the slots in the
rotor.
10. Lightly lubricate rotay seal ring O-ring elastomer and fit into the rear bore of the rotor
11. Align the two flats on the rotary seal ring (105) with the drive flats in the rotary seal drive ring (104) and gently press the
rotary seal ring into the rear bore of the rotor, through the rotary seal ring O-ring (102). On the front face of the seal ring
there is an alignment mark to show the position of the flats on the rear face.
12. Wipe clean the sealing faces with solvent and fit gland guards, rotors, rotor nuts and rotorcase cover.
30

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4.6 Troubleshooting

4. Maintenance

Problem

No flow
Under capacity
Irregular discharge
Low discharge pressure
Pump will not prime
Prime lost after starting
Pump stalls when starting
Pump overheats
Motor overheats
Excessive power absorbed
Noise and vibration
Pump element wear
Syphoning
Seizure
Mechanical seal leakage

Probable Causes

l l Incorrect direction of rotation.

l Pump not primed.



l l l l l l Insufficient NPSH available.



l l l l l Fluid vaporising in suction line.



l l l l l l Air entering suction line.
l l l l l l Strainer or filter blocked.

l l l l l
l
l Fluid viscosity above rated figure.


l l l Fluid viscosity below rated figure.

l l l l Fluid temp. above rated figure.

l l
l Fluid temp. below rated figure.


l l l l Unexpected solids in fluid.
Discharge pressure above rated

l l l
l l l l
l
l l l l figure

l Seal flushing inadequate.

l l
l
l Pump speed above rated figure.

l l Pump speed below rated figure.
Pump casing strained by
l l l
l
l l l pipework.

l l l l Flexible coupling misaligned.
l l
l
l l l Insecure pump driver mountings.
l l
l
l l
l l Shaft bearing wear or failure.
l l
l
l l l Insufficient gearcase lubrication.

l l
l l
l
l l l Metal to metal contact of
pumping element.

l l l Worn pumping element.

l
l Suction lift too high.
l Fluid pumped not compatible
with materials used.
l No barrier in system to prevent
flow passing.
l Pump allowed to run dry.

l
l Faulty motor.

l Pumping element missing

Solutions

Reverse motor.
Expel gas from suction line and pumping chamber and
introduce fluid.
Increase suction line diameter.
Increase suction head.
Simplify suction line configuration and reduce length.
Reduce pump speed.
Increase suction line diameter.
Increase suction head.
Simplify suction line configuration and reduce length.
Reduce pump speed.
Remake pipework joints.
Service fittings.
Increase fluid temperature.
Decrease pump speed.
Check seal face viscosity limitations.
Decrease fluid temperature.
Increase pump speed.
Reduce fluid temperature.
Check seal face and elastomer temp. limitations.
Increase fluid temperature.
Clean the system.
Fit strainer to suction line.
Check for obstructions i.e. closed valve.
Service system and change to prevent problem recurring.
Simplify discharge line to decrease pressure.
Increase flush flow rate.
Check that flush fluid flows freely into seal area.
Decrease pump speed.
Increase pump speed.
Check alignment of pipes.
Fit flexible pipes or expansion fittings.
Support pipework.
Check alignment and adjust mountings accordingly.
Fit lock washers to slack fasteners and re-tighten.
Refer to pump maker for advice and replacement parts.
Refer to pump makers instructions.
Check rated and duty pressures.
Refer to pump maker.
Fit new components.
Lower pump or raise liquid level.
Use optional materials.
Ensure discharge pipework higher than suction tank.
Ensure system operation prevents this.
Fit single flushed mechanical seals.
Check and replace motor bearings.
Fit pumping element.

31

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5. Technical data

5.1 Technical data

5.1.1 Lubrication

Pump Model

Grease capacities

22
23
32
33
42
43

1.0
1.0
2.0
2.0
3.5
3.5

5.1.2 Weights

Pump Model


22

23

32

33

42

43

kg
20.5
21.5
33.5
34.5
60.0
63.0

Bare Shaft Pump

lb
45
47
74
76
132
139

Typical pump and drive unit

kg
lb
67
148
72
158
125
276
128
282
215
474
218
481

5.1.3 Tool requirements

Description

Tool required

22 /23
Screw, rotorcase cover (10)
Socket Size (mm)
17

Torque Setting (Nm)
30

Torque Setting (lbft)
22.1
Nut, rotor retention (22)
Socket Size (mm)
24

Torque Setting (Nm)
80

Torque Setting (lbft)
59.0
Screw, rotorcase retention (3)
Key Size (mm)
6

Torque Setting (Nm)
20

Torque Setting (lbft)
14.8
Screw, canister retention (6)
Socket Size (mm)
8

Torque Setting (Nm)
5

Torque Setting (lbft)
3.7
Screw, torque locking assembly
Key Size (mm)
5

Torque Setting (Nm)
17

Torque Setting (lbft)
12.5
Screw, foot (58)
Key Size (mm)
6

Torque Setting (Nm)
20

Torque Setting (lbft)
14.8
Drain plug (45)
Key Size (mm)
1/8

32

Pump Model
32 / 33
42 / 43
17
17
30
30
22.1
22.1
24
36
120
160
88.5
118.0
6
6
20
20
14.8
14.8
8
8
5
5
3.7
3.7
5
5
17
17
12.5
12.5
6
6
20
20
14.8
14.8
1/4
1/4

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5. Technical data

5.2 Pumphead Clearance information

Radial
Clearance

Front
Clearance

Back
Clearance

Mesh
Clearance
Minimum mesh clearance at any mesh position.
All dimensions in millimeters

Pump
Front
Back
Radial
Minimum Mesh

model
Clearance
Clearance
Clearance
Trilobe


22
0.32
0.20
0.150
0.100

0.16
0.10
0,100



23
0.34
0.20
0.160
0.110

0.18
0.10
0.110



32
0.38
0.20
0.180
0.110

0.20
0.10
0.120


33
0.41
0.20
0.200
0.120

0.25
0.10
0.140



42
0.33
0.22
0.220
0.070

0.17
0.12
0.150



43
0.40
0.22
0.270
0.100

0.24
0.12
0.200

33

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6.1 OptiLobe Pump Range

Parts List
Pos.

Denomination

1
2
3
5
6
7
7A
9
10
11
12
16
17
18
20
21
22
23
24
25
26
27
30
31
36
38
40
49
54
58

Bearing housing
Dowel
Screw, rotorcase retention
Canister
Screw, canister retention
Lip seal, drive end
Carrier, lip seal
Rotorcase
Screw, rotorcase cover
O Ring, rotorcase cover
Cover, rotorcase
Lip seal, gland end
Rotors
O Ring, rotor sealing shaft end
O Ring, rotor sealing nut end
O Ring, canister
Nut, rotor retention
Key
Shaft, drive
Shaft, auxiliary
Bearing, rear
Shim, shaft abutment
Nut, bearing
Bearing, front
Timing gear
Torque locking assembly
Screw, torque locking assembly
Blanking plug
Foot
Screw, foot

34

6. Parts list

 Return to menu

6. Parts list

6.1 OptiLobe Pump Range

This page shows an exploded drawing and includes all items of the pump.

Exploded Drawing

7a

TD 246-046

35

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How to contact Alfa Laval

Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to
access the information direct.