Zenit Group | 22 Apr 2021

GREY - DRG G05M - G08L Assembly

Step by step operations

Position the motor housing horizontally on the bench and secure it with wooden wedges.
Insert the probe cable into the housing seat.
Insert the grommet into the probe and lock it by tightening the cable gland.
Warning: The probe must protrude from the cable gland by approx. 10 mm
Temporarily fix the probe cable onto the outside of the housing with adhesive tape.
Position the stator on the housing so that one of the grooves is at the probe cable.
Position the block on the stator, orienting it appropriately to allow the probe cable to pass through.
Using a press, insert the stator into the housing.
Remove the block and adhesive tape.
Flip the housing.
Insert the bearing retaining washer into the bearing seat.
Place the bearing in the seat.
Place the bearing retaining block on the housing and flip it over.
Position the shaft inside the motor.
Place the upper bearing and its block on the shaft.
Using a press, insert the bearings into the shaft.
Remove the block and place the motor on the bench.
Lock the shaft with the circlip.
Insert the O-ring into the aluminium flange seat and apply grease to it.
Insert the flange into the housing and position it with the block.
Lock the flange with the circlip making sure it is perfectly seated.
Moisten the counterface of the mechanical seal with alcohol and place it in the seat using the block.
Clean the seal thoroughly with a paper towel.
Lightly lubricate the counterface.
Insert the first seal into the shaft and position it with the block.
Lock the seal with the circlip.
Make sure that the shaft can rotate freely.
Soak the second seal in alcohol and insert it into the shaft.
Moisten the second counterface with alcohol and insert it into the pump plate housing with the block.
Insert the locking ring into the seat.
Lock the washer with the circlip making sure it is perfectly seated.
Clean the surface of the seal face with a paper cloth.
Place the O-ring in the seat and apply grease.
Place the paper gasket.
Lightly lubricate the seal.
Place the pump plate on the motor housing and secure it with the screws by tightening them in a criss-cross pattern.
Make sure the shaft can rotate correctly.
Connect the compressed air system to the casing using a connector.
Pour a little alcohol to make sure there are no leaks from the lower seal.
Perform the leak test at a maximum pressure of 1 bar.
The absence of air bubbles guarantees the perfect installation of the seal.
Remove the connector.
Lay the motor on the bench and fill the chamber with oil.
Check the correct quantity in the documentation.
Close the oil chamber with the cap. Use Loctite 243 thread lock or equivalent.
Protect the heat protection and probe cables with a sheath.
Insert the O-ring into the upper bearing support seat and apply grease.
Place the upper bearing support on the motor housing. Use the hole in the holder for routing the cables.
Attach the handle to the motor cover.
Insert the cable gland grommet into the motor cover seat.
Place the cable gland on the motor cover and lead in the screws without tightening them.
Insert the cable into the cable gland.
Insert the cable clamp and lock it in place.
Insert the O-ring into the motor cover seat.
Connect the motor terminals according to the diagram in the documentation and secure them with cable lugs.
Tighten one cable lug to the earth conductor and secure it to the corresponding upper bearing support arrangement.
Connect the motor terminals to the electrical cable and tighten the cable lugs.
Place the motor cover on the housing taking care not to crush the conductors and secure it with screws.
Gently pull the cable until it stops and tighten the locking screws on the cable gland.
Connect the compressed air system to the motor cover using a connector.
Perform the leak test at a maximum pressure of 1 bar.
Disconnect the compressed air hose and remove the connector.
Close the motor cover with the cap. Use Loctite 243 thread lock or equivalent.
Flip the pump and place the impeller on the shaft.
Secure the impeller with the locking screw. Use Loctite 270 thread lock or equivalent.
Position the pump body and secure it with screws
With the gauge, measure the maximum height of the blade from the pump body.
With the gauge, measure the internal height of the intake flange.
Shim as necessary with paper gaskets to obtain a distance of 0.2-0.5 mm.
If necessary, use a little grease to hold the seals in place.
Position the suction flange and fix it to the pump body with the screws.
Check that the impeller rotates freely.
Check with the feeler gauge that the distance between impeller and pump body is 0.2-0.5 mm.