Zenith® Pumps

Installation,Care and Maintenance

ZenithCorrosive DutyGear Pumps

C-9000Gear Pumps

2

Note: Thoroughly read and understand this entire manual before installation and operation of the pump.

Zenith®

Benefits

In 1926, Zenith Pumps was approachedby the synthetic fiber industry to designa pump that would provide precise,pulseless and repeatable flow whileensuring ultimate product quality. Theoptions then were the same as those inthe chemical process industry today—diaphragm, lobe, coarse gear, piston,plunger and screw pumps. Each hasproblems with pulsation, flow inaccura-cies, multiple seal areas and slip, whichrequire constant calibration, high main-tenance and extended downtimes.

Zenith Pumps met the challengeand designed a rotary external gearpump of unique precision and simplicity.

Manufacturing techniques were devel-oped to hold tolerances to ±.00005",minimizing internal clearances andassuring accurate and precise metering.The pump’s simplistic design of onlythree moving parts – two metering gearsand a drive shaft – provided long lifeand reduced maintenance.

For years, engineers have relied onZenith to provide precision fluid han-dling solutions for their most difficultpumping applications. Zenith gearpumps can be found wherever precise,pulseless, and repeatable metering offluids is required.

High Accuracy — Stable, repeatableflows are assured even under varyingconditions of temperature, viscosity andpressure.

Precision Construction — Ground andlapped components allow for operatingclearances to .00015" and provide highvolumetric efficiency.

Minimum Pulsation — Unique designoffers virtually pulseless flow withoutvalves or flexible elements to hinder performance.

Active Flowmeter Concept —Unparalleled mechanical precision,combined with the closed loop set pointaccuracy, ensures an exact volume per revolution without expensive flowmeters.

Low Cost of Ownership — With onlythree moving parts and 316 stainlesssteel compatible construction, the pumpprovides excellent corrosion resistancefor most chemical processes.

Experience — Zenith has over 74 yearsof application experience with engineersavailable 24 hours a day to support yourprecision fluid metering needs.

Specifications Capacities (cc/rev):

0.3, 0.6, 1.2, 2.4, 4.5, 9.0

Recommended Speed:

up to 1000 rpm

Flow Range:

up to 9,000 cc/Minute (2.4 GPM)

Inlet Pressure:

300 psi (20 Bar) Maximum

Outlet Pressure:

1000 psi (70 Bar) Maximum

Differential Pressure:

20 to 1000 psi. (viscosity dependent)

Temperature:

-40° F (- 40° C) Minimum350° F (175° C) Maximum

Seals:Single Mechanical, Double Lip, orMagnetic

Rotation:

Clockwise (CW) facing drive shaft

Port Connections:Metric thread or SAE 61 Standard

Optional Port Adapters:M12 X 1/4" NPT. . . . . . . . . 0.3 – 2.4 cc/rev1/2" SAE X 1/2" NPT. . . . . 4.5 – 9.0 cc/rev

Optional Band heaters:150 Watt, 115 VAC. . . . . . 0.3 – 2.4 cc/rev325 Watt, 115 VAC. . . . . . 4.5 – 9.0 cc/rev

3

Quick Start:

Introduction:

1. If you are familiar with installation of Zenith pumps please read over the list ofDo’s and Don’ts on page 15.

2. Special care must be taken: The C-9000 pumps are easily damaged in handlingdue to the soft metal used in their construction.

3. It is strongly recommended that you thoroughly read through this entire manualbefore you begin installation or any servicing of the C-9000 pumps.

This manual was specifically writtenfor the 0.3, 0.6, 1.2, 2.4, 4.5, and 9.0cc/rev C-9000 pumps. It will guide youthrough the process of maintaining andcaring for your pump.

C-9000 series pumps are similar inconcept to other Zenith pumps, howeverseveral key physical aspects differ in wayswhich will affect the care and maintenanceof the product. The following literature willdiscuss, in detail, how to care and main-tain a well running and efficient pump inorder to maximize the productivity andeffectiveness of your Zenith product.

Below are a few key points whichmust be considered in order to preventdamage to the product during handling,installation and cleaning.

Most importantly

1. Use only brass or plastic tools to pryon the C-9000 pump components;

2. If you must hammer on the pump, usea clean plastic hammer (no imbeddedmetal chips, etc.) and tap lightly;

3. Do not perform maintenance on thesilicon carbide sleeve bearings.

4. Use force, not impact, to move stubborn parts. Again, the C-9000 pumps are not as

hard as the tools found in most mainte-nance areas, and can be damaged bycommon steel tools. This is one feature ofthe pump that must be taken into consid-eration in the installation, disassemblyand assembly procedures.

The specially designed bearingsrequire an interference fit installed at theZenith plant and should not be removedby the customer. These sleeve bearingsare extremely brittle and fragile, and canbe easily broken resulting in multiple partdamage and high replacement cost. SeeFigure 1. The sleeve bearings should notneed to be replaced during routine main-tenance.

If you follow the above suggestionsand the Do’s and Don’ts list (page 15),you will be able to maintain a C-9000pump with little chance of damage.

Figure 1

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Start-Up

Installation: The following is a general installationprocedure for Zenith C-9000 Seriesmetering pumps. The procedure mayvary slightly depending on the pumpmodel purchased. For special applica-tions, considerations, or technical assis-tance, please contact your representativeor our Applications Engineering Group.

Things to remember

1. The pump should be carefullyunpacked and inspected. If any itemsare missing or damaged, the freightcarrier and Zenith should be notifiedimmediately.

2. Take Care! - The pump is a precisioninstrument. Dropping the pump on a hard surface or striking the pump with a hard object can cause serious damage to the components.

3. Treat the pump as a precision gauging instrument.

4. Always flush the piping system beforeconnecting the pump.

5. Filters should be installed upstream ofthe pump. For C-9000 pumps, thefluid should be filtered to five (5)microns, absolute.

6. Zenith C-9000 pumps must never be runwithout a fluid. C-9000 pumps containno lubricant when shipped from thefactory. Prior to start-up, the pumpmust be wetted by priming the pumpwith the process fluid, or by pouringfluid into the inlet port and rotating thedrive shaft until fluid appears at thedischarge port. The product to bepumped can be used as this fluid,assuming it will not evaporate prior tothe pump actually being started.Remove seal housing plug and fillwith compatable fluid. This will ensurethat the shaft seal is lubricated.

7. Turn pumps by hand before start-upto ensure free rotation before startingthe drive.

8. For applications above ambient tem-peratures, if using heaters, heat thepump slowly and evenly (including theseal arrangement) prior to introducinghot fluid into the pump. This preventsthermal shock and material distortion.

9. Make sure that process fluid is in thepump before starting. Apply positivepressure to the pump inlet whenmetering high-viscosity fluids to prevent cavitation.

10. Install a pressure regulating valvedownstream of the pump, if necessary,to ensure there is at least 20 psig differential pressure at all times.

Installing the pumpInstall the selected fittings into the

inlet and discharge ports, taking care notto over tighten the fittings. Mount thepump to the base plate using the twomounting screw holes on the bottom ofthe front plate. Align the pump shaft tothe shaft on the gear reducer using ashaft alignment gauge, laser alignmentmechanism, or by carefully using astraight edge to control the couplingalignment. Jaw-type couplings are notrecommended as shaft misalignmentmust be controlled to within .008 inchparallel and to within 1° angular. ForZenith-supplied systems (pump, reducer,baseplate, coupling, etc.), the shaft mis-alignment should be controlled to within.035 inch parallel and to within 1° angular,but these values may need to be adjusteddepending on the particular couplingchosen for your application. Wheninstalling the coupling end member ontothe pump shaft, do not use excessiveforce. This connection should be a slip fit.If not, increase the inside diameter of thecoupling accordingly.

If your pump was designed to use anouter drive gear, you must grease theouter drive gear and carefully mesh itwith the drive pinion gear. A backlash of.005” is recommended.

1. Allow enough time for all componentsof the system to reach process tem-perature before starting the pump.Apply inlet pressure to the pump,allowing time to ensure that theprocess fluid has entered the pump to prevent the bearing areas from running dry.

2. Before starting, remove all flow restrictions downstream of the pump

to provide initial operation with theslightest amounts of back pressure.

3. Set the acceleration rate for the pump tobe 0.3 seconds/rpm or more. Prior tostart-up, adjust the acceleration rateof the controller to ensure initial slowspeed operation. This corresponds to600 seconds to reach 2000 rpm, or .3seconds/rpm.

5

Start-Up (cont.) 4. Start the pump and accelerate to 30 rpmor to the lowest set point of speed for theapplication, whichever is less. Watch thepoint of discharge for evidence offluid. If no discharge is seen after 10revolutions of the shaft shut down thepump and check for obstructions inthe system and proper pump rotation.This is assuming a connection can bebroken within a few inches of thepump outlet port, where the flow wouldbe evident within several seconds. Ifthe distance between the pump outletand the point of discharge inspectionwere long, more time would be neededbefore flow is confirmed. This is morerisky, and damage to the pump mightresult if it is run dry for more than 30seconds.

Note: The pump will discharge a cloud ofbubbles when it is started, but thiswill subside when the air is purgedfrom the pump. This is a normalpart of pump startup.

5. When smooth flow is seen at the dis-charge the pump and system can begradually brought up to normal oper-ating speeds and pressure. Listen forunusual sounds when first starting thepump and turn the pump off immedi-ately if any are heard. Investigate forcauses of distress.

6. If, at any time during operation, thepump does not appear to be runningsmoothly, stop the pump immediatelyto avoid serious internal damage.

Flushing of the product pipingTake care when flushing the pump or

downstream process equipment usingthe Zenith precision metering pump asthe flushing pump. The pump must beable to withstand the solvent or flushingagent as well as the product, and the

operating speed and pressure duringflushing must still fall within the applicablerange for the C-9000 product.

If it is necessary to flush the system,the following suggestions are recom-mended to prevent pump damage:

1. Minimize the differential pressureacross the pump ports to less than100 psi, but not less than 20 psi.

2. Reduce the pump speed to anacceptable level, approximately 50-100 rpm.

3. Flush the pump for the shortest allowable time, yielding effectivecleansing of the system, and nolonger than necessary.

4. Another alternative is to use a bypassaround the pump, as illustrated inFigure 2, this will allow for high velocityflushing of the downstream systemwhile minimizing risk to the meteringpump. During the flush cycle, run thepump slowly. The fluid will passthrough and around the pump. Thiswill allow the system to be flushedquickly and effectively.

5. If it is necessary to also flush the sealhousing, and the discharge pressureis higher than the suction pressure(during flushing cycle), connect theseal housing drain to the suction line(dotted line on Figure 2).

Pump

ValveBypass

Figure 2

Care DuringOperation

How does the pump work?Fluid enters the pump through the

inlet port located in the front plate andfills the gear pocket. As the gears rotate,a precise amount of fluid is trappedbetween the side walls of the gear pockets and gear teeth.

The metered fluid is transported by therotation of the gears to the discharge sideof the pump where the gear teeth comeinto mesh. This action forces the fluid out ofthe gear teeth and through the outlet port

located in the front plate. The pressuredeveloped is determined by the pumpsize, the gear clearances, pump speed,fluid viscosity and impedance to flow.

How fast can I run the pump?Pump speed is limited by practical

considerations. If a high viscosity fluid isbeing metered and pump speed isincreased beyond a certain point, thefluid may not be able to fill the gear teethspaces, and the pump will not obtainenough fluid to maintain normal volumetric

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Care DuringOperation (cont.)

efficiency. Lack of sufficient fluid is calledstarvation or cavitation. This can beremedied by increasing the inlet pressureor reducing pump speed.

Pumping thin fluids requires a differentapproach. Since the pump depends uponthe metered fluid for lubrication of internalbearing surfaces, speeds are normallylimited. These bearing surfaces include thebearing areas in the front and rear plates.Operating a Zenith pump above indicatedspeeds will accelerate wear and may causeseizure, especially if the fluid is a poorlubricant at operating temperatures. It is notrecommended to pump abrasive fluids withC-9000 pump models. In certain applica-tions, it is recommended to use a pump oflarger capacity operated at a lowerspeed. Contact your representative or ourApplications Engineering Department forassistance with this special case.

Inlet Pressure RequirementOnce the pump is installed the inlet

port pressure must be found and adjustedto an acceptable level. It is highly recom-mended that the inlet port pressure be atleast one atmosphere. It is, however,acceptable to have 0.5 atmosphere oreven vacuum at the inlet assuming theport is flooded. It is also imperative thatthe pumping losses from the tank to theinlet port be considered in this procedure.A high viscosity fluid requires a high inletpressure; a low viscosity fluid requires alow inlet pressure. Once the pump hasstarted cavitation will occur if the inletpressure is not high enough. Cavitationmay damage the pump so if it occursstop the pump immediately. Keep in mindthat once the inlet is flooded and thepump is started there will be a head lossacross the inlet port of the pump. Table 1on the next page has been included forreference.

De-rating the Pump Performance Pump displacement depends on four

basic variables: fluid viscosity, gear clear-ances, differential pressure and pumpspeed. The pump performance is de-rated, or reduced from the ideal value,due to slip of the product fluid around thegears from the discharge side back tothe intake side.

The less viscous the fluid, the morelikely it is to flow through a given orifice.For de-rating the pump, this orifice is thegear clearance. Differential pressureforces the fluid through this clearance ata steady rate, regardless of the pump

speed. Thus, the slip flow is constant fora given amount of time. The actual deliveryof fluid is the measured delivery minus theslip. This means the pump displacementis still linear. If we increase the pumpspeed we increase the measured deliv-ery, while the slip remains constant. Slipflow is repeatable and predictable, andpump operation can be adjusted to compensate for this flow.

Graph 1 on the next page has beenincluded for reference.

Operating at elevated temperaturesZenith C-9000 Series pumps are

designed for operating temperatures lessthan 176°C. When operating at tempera-tures above ambient, heaters should beused, and pumps should be heated slowlyand uniformly to avoid distortion andinternal component interference.

Magnetic Coupling PumpsIn normal operation, the magnetic

poles of the outer drive magnet remainaligned with the magnetic poles of theinner pump magnet. The motion of themotor is smoothly transferred to the pumpshaft. If the torque load on the pumpexceeds the magnetic coupling strength,then the outer magnets will rotate pastthe inner magnets and the magnetic poleswill misalign. The outer magnet willincrease to a no-load motor speed whilethe inner magnet remains relatively motion-less. Excessive noise and vibration canbe observed as the poles of a decoupledmagnet move past one another.

The pump should be stopped immediately if the magnets decouple.Continued operation of the motor with themagnets decoupled will reduce the futurestrength of the coupling. The magnets willnot properly realign until the motor hasbeen stopped. Before restarting themotor, one should determine the cause ofthe decoupling and remedy the problem.Decoupling does not necessarily indicatea pump failure. It indicates that an instan-taneous torque requirement of the pumphas exceeded the strength of the mag-netic coupling supplied with the system.

Without disassembly of the pump itcan be difficult to determine whether themagnetic coupling or the pump internalsare operating incorrectly. The following isa list of examples that could result inmagnet decoupling:

• Blockage or restriction in the discharge side of the system

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• Discharge pressure in excess of nominal conditions

• Too rapid acceleration or decelerationof the drive system

• An increase in fluid viscosity• Foreign particles impinging upon

pump internal components• Increased friction due to a poorly

lubricating process fluid

The decoupling characteristic of mag-nets can be a safety feature, preventinginadvertent pump/motor overloads.Magnets should be chosen so that theirdecoupling torque is greater than thepump input torque. This should includeany transient, starting, and stopping con-ditions in addition to steady state values.

The decoupling torque can vary withdifferent fluids, temperatures, operatingpressures, and magnet sizes. Accuratesizing of magnets for a specific application requires precise knowledge ofseveral operating conditions. Check withyour Zenith representative to see which9000-MD system is appropriate.

General Magnetic CouplingPrecautions

Both the inner and outer magneticrotors are very powerful. Handle them withcaution.Danger! Persons with cardiac pacemakersshould stay at least 8 feet from the magnetic product at all times.

Do not position hands or fingers sothat they may become trapped betweenthe two magnetic rotors, or between onemagnet and a metal object.

Do not position the magnets near oneanother unless assembling the pump to thesystem. Both rotors should be fastened totheir respective shafts before bringingthem into proximity.

Do not place the magnets near anyelectronic equipment or media that issensitive to magnetic fields ( computers,diskettes, credit cards, etc.)

When storing and assembling themagnetic coupling, make sure that nosmall metallic fasteners, pieces or otherforeign objects adhere to the rotors orbarrier cap.

If the magnets de-couple, stop thedrive system for the pump immediately.Determine the cause of the excessivetorque requirement and remedy the problem prior to re-starting the system.

Care DuringOperation (cont.)

Key:∆P = Pressure (psi)µ = Viscosity (cp)N = Speed (rpm)

0.000.001 0.01 0.1 1 10 100

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

∆P/(µ•N)

Dera

ting

Fact

or

0.3 cc/rev

4.5 cc/rev9.0 cc/rev

0.6 cc/rev

1.2 cc/rev2.4 cc/rev

C-9000 Pump PerformanceGraph 1

Inlet Pressure Loss (psi) = Viscosity(cps) • Displacement(cc/rev) • Shaft Speed(rpm) • [(Specific Gravity • W1)+W2]

Note: This sizing procedure should be used as a guideline for estimating pump type, pump size and system requirements. Please consult Zenith to confirm pump and system selection prior to placing a purchase order.

Flowrate = pump capacity (cc/rev) x rpm x performance factor

WARNING

cc/rev W1 W20.3 4.29E-06 2.32E-060.6 1.93E-06 2.47E-061.2 1.21E-06 2.77E-062.4 9.34E-07 3.38E-064.5 3.00E-07 3.46E-079.0 2.24E-07 4.19E-07

Table 1

8

Cleaning,Inspectionand Repair

REMEMBER: Zenith metering pumpsare made for exacting duty. In order todevelop high pressure and minimize slipflow, the clearance between the meteringgears and the housing must be as smallas possible, yet large enough to allowadequate lubrication. All parts aremachined to extreme accuracy. Criticaldimensions are held between one andtwo ten-thousandths of an inch (2 to 5µ).Consistent performance is dependentupon proper handling. Please handle the pumps with extremecare and set aside a separate clean areafor pump maintenance and repair.

It is recommended that pump usersinstitute a program for dimensionalinspection of critical parts in order tokeep maintenance and operating costs toa minimum. By noting the performance of

a pump immediately before removing itfrom service and correlating the perfor-mance to measured component wear, the maximum wear limits for the pump’scritical components can be established.Additionally, the service life of the pumpcan be predicted and downtime can bescheduled accordingly.

If necessary, any Zenith precisionmetering pump requiring maintenancecan be returned to the factory for completerepair and overhaul. For a large number of pumps, Zenith offers a contract repair service, which helps to reduce repaircosts and delivery time. Zenith Pumpsalso offers pump maintenance seminars.For more information concerning Zenithpump repair services, please contact ourCustomer Service Department.

C-9000 SeriesDisassembly

Instructions below assume the pump has been removed from the system, forexample magnetically driven pumps withadapter plates have been disengagedfrom the housings.

Note: As parts are disassembled, place themcarefully on a clean surface such as a softcloth. See Figure 3. Do not allow them totouch each other. Pay close attention to theorder in which parts are removed. This willaid in the reassembly of the pump. The numbers in parentheses refer to the partnumbers on the bill of materials.

Caution: Please review the precautionslisted on Page 7 for MagneticallyCoupled Pumps.

1. If the pump came with an outer drivegear, remove it from the drive shaftbefore starting disassembly.

2. Remove the square key (17) from the shaft end.

3. If applicable, remove the socket headscrews (18) from the seal housing (11).See Figure 4.

4. Lift off the seal housing (11). Take careto also remove the o-ring (33) whichseals the housing to the front plate. Thering may be attached to the front plate.

5. Remove the seal (51) [item 13 on 4.5 & 9 cc/rev pumps] from the seal housing (11).

a) Mechanical Face Seal Pumps; Theceramic seat of the mechanical faceseal may be removed from the sealhousing by pushing it out with fingerpressure. If it is stuck, use two small

Allen keys or other small pins to pressthe seat from the housing using the twoaccess holes in the housing face. Setscrews will have to be loosened to allowremoval of the mechanical seal (13)from the drive shaft. Some materials ofthe seal (face) are brittle in nature, useextreme caution so as not to damagethe seal or its components. Remove theretaining ring (16) from drive shaft witha brass or plastic tool.

b) Double Lip Seal Pumps; Press the lipseal (51) [item 13 on 4.5 & 9 cc/revpumps] from the housing using fingerpressure, or by pressing on the sealusing a plastic tool.

Figure 3

Figure 4

9

C-9000 SeriesDisassembly(cont.)

C) Magnetically Coupled Pumps

If applicable, remove the screws thatsecure the barrier cap to the adapterplate. Remove the barrier cap and itsO-Ring. NOTE: There could be processfluid contained in the barrier cap. Loosensetscrew at the bottom of the inner rotorwith appropriate Allen wrench. NOTE:Beware of strong magnetic forces.Slide the inner rotor off the shaft.

Remove the square key from thepump shaft. Remove the four sockethead screws/washers securing theadapter plate to the pump body. Liftthe adapter plate off the pump bodyand retrieve the O-Ring.

6. Now set the pump in a vice that hassoft, protective jaws made of brass, aluminum, plastic or any material softerthat 316ss. Orient the pump with thedrive shaft pointed down. Allow thevice to grip the pump on the port sidesof the front plate.

7. Loosen and remove the socket headscrews (19) [and 15 if applicable], fromthe back of the rear plate (7).

8. Remove the rear plate (7). Always usethe pry slots to prevent scratching theprecision lapped surfaces. Use brass or plastic tools to pry, if necessary. Takecare not to press on the gears or theedges of the gear pocket.

Caution: Do not allow the gears to be liftedout of the gear plate. They may drop,causing damage to the gear teeth. SeeFigure 5.

9. Remove the drive shaft (2) and the driving gear (5). The round key (4) willfall from between the gear and thedrive shaft.

10. Remove the retaining ring (16) from thedrive shaft with a brass or plastic tool.

11. Remove the arbor (9) and the drivengear (5) from the gear plate (3). Note:The driven and driving gears areidentical in most models.See Figure 6.

12. Remove both retaining rings (16) fromthe arbor (9) using brass or plastictools. Remove the driven gear (5)from the arbor (9). See Figure 7.

13. Remove the round key (4) from the arbor (9).

14. Remove the gear plate (3). Alwaysuse the pry slots to prevent scratchingthe plates!

Caution: The slip-fit dowels (10) maycome off with the gear plate.

15. Remove both slip-fit dowels (10) byturning and pulling simultaneously. It is acceptable to lightly press thedowels out using an arbor press. Use a brass or plastic pin to pressagainst the dowel.

16. Remove the o-rings (34) from the frontand rear plates with a brass or plastictool.

17. Do not attempt to remove the specialbearings located in the front and rearplates. See Figure 8.

Figure 5

Figure 6

Figure 7

Figure 8

10

0.3 - 2.4 cc/rev C-9000

18 SHCS M6x1

11 Lip Seal Housing

23 Sleeve Bearing

24 Sleeve Bearing

45 Spacer Bushing

45 Spacer Bushing

20 Rear Plate

3 Gear Plate

21 Front Plate

10 Hollow Dowel

9 Arbor

Round Key 4

Drive Shaft 2

Driving Gear 5

Rear Plate Assembly 7

SHCS M10x1 19

SHCS M6x1 15

Front Plate Assembly 8

O-Ring 33

O-Ring 34

Tandem Lip Seal 13

Dryseal Type Plug 42

Interpret per ASME-Y14.5M 1994

Square Key 17

18 SHCS M4x 0.7

11 Seal Housing

23 Sleeve Bearing

16 Retaining Ring

24 Sleeve Bearing

35 Dryseal Type Plug

2 Drive Shaft

20 Rear Plate

3 Gear Plate

21 Front Plate

10 Hollow Dowel

9 Arbor

Round Key 4

Driving Gear 5

Rear Plate Assembly 7

SHCS M6x1 19

Front Plate Assembly 8

O-Ring 33

O-Ring 34

Tandem Lip Seal 51

Interpret per ASME-Y14.5M 1994

Square Key 17

4.5 & 9.0 cc/rev C-9000

11

Inspectionand PartPreparation

After the parts have been cleaned,they should be inspected for nicks, burrsand stubborn residue. The gears and theedges of the gear plate pockets are themost likely areas to be damagedbecause of the sharp edges on theseparts. An illuminated magnifier helps during the examination.

Components should be cleaned with a soft brush and a mild detergentsolution, or a safe, industrial solvent. Do not use abrasives to clean the pump.

Carefully inspect for any tool marks,nicks or scratches on the surfaces of theplates and gears. See Figure 9. Watch forshiny areas around nicks or scratches onthe plates. These indicate a raised areathat is present. This damaged area needsfurther attention. It is acceptable to care-fully stone a “cratered” nick with a new,hard Arkansas or X-Fine water stone(6000 grit or higher), but this should bedone with extreme care.

Deep marks or galling cannot beremoved by stoning. These surfaces mustbe ground. Return the parts to the factoryfor repair or replacement.

Any nicks in the gear teeth should beremoved by carefully stoning the partswith a fine India oilstone or an Arkansasstone. After all preparation has beencompleted, remove the abrasive dustand loose residue in an ultrasonic cleaneror other suitable cleaning method.Abrasive dust is larger in size than thepump clearances.

Always use clean, lint-free rags ordisposable towels and compressed air toclean components. Common paper towelsare not acceptable because they canleave small pieces of paper and dust onthe pump parts. Use chemical brushes to clean between gear teeth, bores andother pump features. After all componentsare clean, the pump can be reassembled.See Figure 10.

If cleaned parts are not to bereassembled for a period of time, theyshould be carefully packed in soft paperto prevent damage during storage. Neverallow C-9000 parts to touch each other instorage or during cleaning. These com-ponents can easily damage each other if they collide by shifting around in a panor bin.

New and replacement parts shouldalways be deburred and cleaned using theabove procedures. In addition to the abovemethods, new gears must be deburredon the teeth tips and edges using 600grit paper, as well. Roll the gear for tworevolutions like a wheel against the abra-sive paper. Press down gently on thegear during this process. Simulate amotion as if you were trying to sand theteeth off of the gear; perform only twocomplete turns. Now, hold the gear andsweep the edges of the teeth against thepaper for two revolutions of the gear.Finally, lay the gear flat on its side andblock as discussed above. Repeat thisblocking on the other side of the gear.Sharp edges on the gear bores must alsobe broken.

Figure 9

Figure 10

12

C-9000Series Reassembly

Use all pages of the assembly drawingduring the reassembly process to assurecorrect orientation of the partsNote: If the pump will not turn freely after acomponent is installed, then the pump needsto be inspected further to determine wherethe unwanted contact is occurring.

Caution: Please review the precautionslisted on Page 7 for MagneticallyCoupled Pumps.

Provide a can of compatible lubricant,preferably a mineral oil or process-acceptable synthetic lubricant such asglycerin. If none of these materials areavailable it is acceptable to use rubbingalcohol as a substitute lubricant. Shaft,arbor, dowels, and gears should be lubricated prior to assembly. Take care to remove excess fluid from between the plate surfaces using a clean, lint-freetowel. Threads on bolts should be lubricated with an anti-seize compoundor a molydisulfide based grease SeeFigure 11. During assembly, considerablecare should be taken to prevent wedgingor jamming of close-fitting components.Never force the parts together. They will drop or press into place with fingerpressure if properly aligned.

1. Insert the o-rings (34) into the grooveson the front and rear plates (8,7).Replace these o-rings if they havebeen damaged.

2. Place the front plate (8) in a vise thathas soft protective jaws. Grip the pumpon the port sides of the front plate withthe inner surface of the plate facing up.

3. Push both slip-fit dowels (10) into thedowel holes in the gear plate (3).

4. Place the gear plate (3) on the frontplate (8) and align the dowels so theyslip into the corresponding holes onthe front plate. Make sure that the boltholes also line up when fitting the gearplate on the front plate. See Figure 12.

5. Place the round key (4) on the arbor(9) and fit the driven gear (5) on to thearbor. Note: The driven and drivinggears are identical in most models.

6. Snap the retaining rings (16) onto the arbor and slip the arbor into thefront plate (8).

7. Install the round key (4) into the keyway on the drive shaft.

8. Slide the driving gear (5) onto thedrive shaft and against the retainingring. Take care to align the keyway inthe gear with the key (4). The key mayneed to be held down to prevent itfrom being damaged by the gear

9. Insert the drive shaft (2) into the frontplate (8) and insert the gear into thegear pocket of the gear plate (3). SeeFigure 13.

10. Install the rear plate (7).

Figure 11Figure 11

Figure 13Figure 13

Figure 12

13

C-9000Series Reassembly(cont.)

11. Lubricate the threads and install thesocket head screws (19) through therear plate (7). Torque the screws to50% of recommended torque (seetable page 14) using a crossing pattern. Check for free rotation of thegears. If acceptable, continue totorque to total recommended torque.Again, check for free rotation of thegears. See Figure 14.

12. Place a seal installation tool (lip sealversion only) (52) [item 41 on .05-2.4cc/rev pumps] over the end of theshaft.

Note: For Magnetically Coupled Pumps noseal installation tool is required.Insert the smaller O-Ring into the grooveon the adapter plate, using compatiblegrease to retain the O-Ring into thegroove. Install the plate with the O-Ringfacing the pump body using the foursocket head screws and sealing washers.Insert the square key onto the pumpshaft, then slide the inner magnet ontothe shaft. Refer to certified pumpassembly drawing to determine the correct height/placement of the magnet.Note: This is critical to the pumps properoperation. Secure the inner magnet bytightening the setscrew upon the squarekey. Place the larger O-Ring into theexposed face of the adapter plate.Lower the barrier cap into position overthe inner magnet. If applicable mountthe barrier cap by installing/tighteningthe eight socket head screws.

Assembly is now complete.

13. Mechanical Seal Installation

a) Snap the retaining ring (16) onto thedrive shaft. Install the mechanical seal (13) onto the drive shaft with thecarbon end away from the front plate.Take care when pressing the seal ontothe shaft. The elastomer can be damagedby the keyway or shaft edge.

b) Align the set screws with the groovesmachined in the drive shaft and tightenthe set screws.

c) Install the ceramic seat in the sealhousing (11) with the 0-ring of the seat away from the mechanical seal.

14. If your pump contains a double lipseal (51) [item 13 on 4.5 & 9 cc/revpumps] push the seal to the rear ofthe seal housing. Make sure there isno gap between the seal and the seal housing.

15. Install the o-ring (33) into the recess in the seal housing (11). If necessary,use compatible grease to keep the o-ring in place. Note: This ring mayalready be in place if the pump waspreviously assembled.

16. Install the seal housing (11) over thedrive shaft (2). See Figure 15.

17. Lubricate the socket head screws andinstall them (18) into the seal housing(11). Tighten to the recommendedtorque remembering to use a crossingpattern.

18. Install the square key (17) into thedrive shaft keyway.

Figure 14

Figure 15

14

Pump Bolt Size Bolt Material RecommendedTorque (lb.-in)*

M4 316 SS 20M6 316 SS 70M8 316 SS 169M10 316 SS 335M12 316 SS 580

Mounting Bolt Bolt Material RecommendedSize Torque (lb.-in)*M10 Alloy 519M12 Alloy 910

Trouble Probable Cause Remedy

Pump will not turn 1) Drive malfunction Verify that drive is powered. Assure that alarm circuits areclear. Check motor drive current and speed settings.

2) Process conditions Check process conditions changed for proper temperature,

pressures, viscosities and materials.

3) Entrained particle Disassemble and clean pump; replace any damaged parts.

4) Possible internal Disassemble and clean damage pump; replace damaged

parts. Consult factory.

Excessive seal 1) Worn seal face(s) Replace seal.assembly leakage

2) Improperly Positioned Check seal and faces forseal or faces proper position.

1) Excessive outlet Reduce outlet pressure.pressure

Reduced pump 2) Worn gear(s) Replace worn gear(s).efficiency

3) Process conditions Consult factory for gear changed clearance recommendations

for new process conditions.

Trouble-shooting

Screw Torque

Examples of malfunctions of the pump with possible causes and remedies are listed in the following table:

*Lubricated values/if non-lubricated increase by 33%.

15

Do’s

Handle with care - The pump can bedamaged by common steel tools.

Disassemble the pump in a clean areaand keep the area clean during maintenance.

Cover the workbench with a clean clothor with paper towels.

Change the towels on the bench as necessary to ensure the area is cleanduring maintenance and assembly.

Keep prying and scraping tools andhammers used on C-9000 product separate from those used for othermaintenance tasks

Pry only with clean, new brass or plastic tools and pry in designatedareas only.

Tap lightly with clean plastic or rubberhammers.

Lubricate the threads on screws andbolts with an anti-seize compound orwith molybdenum disulfide grease.

Tighten the bolts with torque wrenchesto the specified torque.

Tighten the bolts in a crossing pattern.

Avoid touching the bearings with anyhard object.

Use the seal installation tool providedwhen reassembling the pump.

Clean the pump with water andapproved liquid solvents. “Soft” abrasive cleansers are acceptable(kitchen and bath cleansers that won’tscratch.)

Don’ts

Don’t pry, tap, scratch, scrape or otherwise work on the pump or its components with steel tools.

Don’t assume that because it is steel youcan’t damage the pump in handling.

Don’t work on the pump in a dirty area.

Don’t work on a bench which is not covered. Hard particles imbedded inthe bench can cause damage to thepump parts.

Don’t use dirty or damaged tools, orthose that might have hard particlesimbedded in them.

Don’t use steel prying tools.Don’t pry with edges or corners of

the tool.Don’t pry with broken or damaged tools.

Don’t tap with steel tools or hammers.Don’t use hammers with imbedded

particles in the hammer faces. Useclean, new tools.

Don’t assemble the pump without lubricating the bolt threads.

Don’t tighten the bolts without using atorque wrench.

Don’t tighten the bolts all the way in thefirst attempt, and don’t tighten them ina circular order.

Don’t attempt to remove the bearingsfrom the plates. The bearings can be easily broken and the plates damaged in the process.

Don’t attempt to install the seal without theseal installation tool and instructions.

Don’t clean the pump using abrasives or by bead or sand blasting.

Don’t burn the pump out in a furnace.

FAILURE, IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED

HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.

This document and other information from Zenith Pumps, itssubsidiaries and authorized distributors provide product and/orsystem options for further investigation by users having technicalexpertise. It is important that you analyze all aspects of your application and review the information concerningthe product or system in the current product catalog. Due to thevariety of operating conditions and applications for these productsor systems, the user, through its own analysis and testing, is solelyresponsible for making the �nal selection of the products and systems and assuring that all performance, safety and warningrequirements of the application are met.

The products described herein, including without limitation, product features, speci�cations, designs, availability and pricing, are subject to change by Zenith Pumps and its subsidiaries at any time without notice.

WARNING

© Copyright 1998 Zenith Pumps C-9000 C&M 10/04

Zenith® Pumps1710 Airport Road

Monroe, NC 28110Phone: 704-289-6511 • Fax: 704-289-9273

zenithpumps@colfaxcorp.com • www.zenithpumps.comA Colfax Buisiness Unit

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