Work Shop ABS AFP

ABS submersible sewage pump AS
ABS submersible mixer pump RW

ABS Piranha submersible grinder pump
15975727 (01/2007)
GB Workshop Manual
www.absgroup.com
Workshop Manual
ABS submersible sewage pump AS / ABS submersible mixer RW / ABS Piranha submersible grinder pump
ABS submersible sewage pump AS

0530 0830
0630 0840
0641
ABS submersible mixer RW
200 280
ABS Piranha submersible grinder pump

S10/4 (50Hz & 60Hz) S17/2 (50Hz)
S12/2 (50Hz) S21/2 (50Hz)
S13/4 (50Hz) S16/2 (60Hz)
S26/2 (50Hz & 60Hz) S30/2 (60Hz)
S18/2 (60Hz)
Contents
1 Health and Safety Instructions.......................................................................................................................................................3
2 General.............................................................................................................................................................................................4
2.1 Dimensions and Weights...................................................................................................................................................................4
2.2 Tightening Torques ...........................................................................................................................................................................4
3 Motor Unit........................................................................................................................................................................................5
4 Wet Ends..........................................................................................................................................................................................6
4.1 Wet End AS / Vortex Impeller............................................................................................................................................................6
4.2 Wet End AS / CB Impeller.................................................................................................................................................................7
4.3 Wet End AS / CB Impeller.................................................................................................................................................................8
4.4 Wet End Piranha Hydraulics.............................................................................................................................................................9
4.5 Wet End RW Hydraulics..................................................................................................................................................................10
5 Oil Filling and Oil Change.............................................................................................................................................................11
6 Mechanical Seal - Removal & Refitting.......................................................................................................................................12
7 Motor Cable & Cable Cap connection - Stator Removal............................................................................................................13
8 Rotor Shaft and Bearing removal................................................................................................................................................14
9 Test Procedure .............................................................................................................................................................................15
10 Troubleshooting Tips....................................................................................................................................................................16
11 Tool Drawings................................................................................................................................................................................17
11.1 Tool Drawings - Stator Insertion......................................................................................................................................................17
11.2 Tool Drawings - Mechanical Seal Insertion.....................................................................................................................................18
11.2 Tool Drawings - Mechanical Seal Insertion.....................................................................................................................................19
11.3 Tool Drawings - Lip Seal Insertion...................................................................................................................................................20
13.4 Tool Drawings - Pressure Test.........................................................................................................................................................21
13.5 Tool Drawings - Stator Extraction....................................................................................................................................................22
13.6 Tool Drawings - Stator Pullers.........................................................................................................................................................23
13.7 Tool Drawings - Impeller Pullers......................................................................................................................................................24
13.8 Tool Drawings - Bearing Press........................................................................................................................................................25
13.9 Tool Drawings - Bearing Support.....................................................................................................................................................26
ABS reserves the right to alter specifications due to technical developments

Workshop Manual
1 Health and Safety Instructions

When carrying out any repair work the Brochure “ Health and Safety Instructions” as well as instructions in the
Installation and Operating Instructions must be observed.
Prior to starting with any maintenance work the ABS units must be completetly disconnected from the mains by
a quilified person and protected from being inadvertently switched back on.
m
Prior to maintenance, any units, which have been used in contaminated media, e.g wastewater
containing faeces, must always be cleaned and, if necessary, be thoroughly decontaminated. The
specfic regulations for hygiene of the respective application countries must be observed.
When carrying out any repair or maintenance work, the safety regulations covering the working in enclosed
areas of sewage installions, as well as “good technical practice” must be observed!
m
Before removal of units in hazardous areas the sump and surrounding area must be adequately
vented to avoid danger of a spark causing an explosion.
c
Warning dangerous gases
Observe all accident prevention measures and regulations!

Please use a safety belt and a life line when getting into the sump and work together with supervisory staff.
m
Ensure adequate venting
ATTENTION Repair on explosion-proof motors may only be carried out by workshops or

persons authorised for this. During repair work only original parts supplied by the
manufacturer must be used! Lifting equipment like hoists, shackles wire ropes and
wire clamps etc. must intervals undergo a visual examination at regular intervals
(approx. every 3 months) for wear and corrosion. If necessary, those parts must be
replaced! Installation accessories (in particular for mixers and aerators must undergo
a visual examination at regular intervals for wear and corrosion etc. and if necessary,
those parts must be replaced.
m
Changing the direction of the rotation at control panels without changeover switch should only
be carried out by a qualified person and for this reason this procedure is not allowed for cleaning
hydraulics or propellers.
m
The oil in the chambers and gearboxes (if present) of the ABS units may be under pressure. Before
opening the oil drain plug, please always put a cloth over the oil filler screw, loosen it and screw it
down again! The regulations covering oil and grease or cooling liquids must be observed, any waste
oil, grease or cooling liquid should be correctly disposed of.
Workshop Manual
2 General
2.1 Dimensions and Weights
ATTENTION Note the entire weight of the ABS unit! (see nameplate). The dimensions of the unit
can be found on the relevant dimensional sheet on our ABS Internet data base EPM
(Electronic Product Manual). The hydraulic curves and impeller types can be found
on the hydraulics curve sheet. The technical data and weight of the unit can be found
on the nameplate.
m
The ABS units are prepared for transportation by placing them on an adequately strong horizontal
surface. Care should be taken that they cannot fall over. The hoist must be adequately dimensioned
for the total weight of the ABS units (incl. all accessories which may be fitted) and must comply with
the local valid safety regulations. Do
��
not stay or work in the swivel area of a suspended load! The
lifting hook height must take into consideration the height of the ABS units as well as the length of the
lifting chain.
2.2 Tightening Torques

Tightening torques for ABS stainless steel screws:
M6 7 Nm
M8 18 Nm
M10 33 Nm
M16 114 Nm
M12 57 Nm
M20 158 Nm
M24 280 Nm
In case of screwed conections, using “Nord-Lock” securing washers

(e.g impeller fixing screw) the torque figures given above should be increased by 10%!
Workshop Manual
3 Motor Unit
Position Description
1 Screw Cyl
2 Cable

3 Cable Cap
  4 Washer
5 Cable Seal
  6 Washer
7 Toothed Washer
 
8 Cable Eyelet
 
9 Screw Slot Hd
 10 Stator
  11 Butt Splice
12 O-Ring
13 Bearing
14 Rotor
15 Bearing Lid
16 Washer
    17 Bearing
18 Circlip
19 Circlip
 20 Lip Seal
21 O-Ring
 22 Screw Cyl
23 Motor Housing
24 Earth Bracket
 25 Washer Spring
26 Screw Slot Hd

27 Nameplate
28 Pin Round Head
29 Seal Ring
30 Screw Cyl

31 Washer Seal
32 Impeller Key










Workshop Manual
4 Wet Ends
4.1 Wet End AS / Vortex Impeller
1 Volute
2 Mechanical Seal
3 Circlip
 4 Impeller
5 Washer
6 Screw Hex
7 Bottom Plate
8 Screw Cyl
Removing Impeller.
Remove screws (8).
Remove bottom plate (7).
Remove screw (6).
Remove washer (5).
 Remove impeller (4) using
impeller pullers.
Refitting Impeller.
 Add grease to the shaft.
Fit impeller (4) to shaft.
Fit washer (5) and screw (6).
Fit bottom plate (7) to volute (1).
 Fit screws (8).

Workshop Manual
4.2 Wet End AS / CB Impeller
 1
2
Volute
Mechanical Seal
3 Circlip
4 CB Impeller
5 Washer
6 Screw Hex
7 Bottom Plate
8 Washer
9 Screw Cyl
Removing Impeller.
Remove screws (9).
 Remove washers (8)
Remove bottom plate (7).
Remove screw (6).
Remove washer (5).
Remove impeller (4) using
 impeller pullers.
Refitting Impeller.
Add grease to the shaft.
 Fit impeller (4) to shaft.
Fit washers (8) and screw (9).
Bottom plate.
Fit bottom plate (7) into volute (1) until
there is contact to the impeller (4).
 Rotate bottom plate (7) slightly clockwise
off of impeller (4).
Allow 0.3mm to 0.5mm clearance between
bottom plate (7) and impeller (1).
 Fit washers (8) and screw (9).
Secure screws (9) tightly.
Check that impeller (4) rotates freely.

Workshop Manual
4.3 Wet End AS / CB Impeller
 Position Description
1 Volute
2 Mechanical Seal
 3 Circlip
4 CB Impeller
5 Washer
6 Screw Hex
 7 O-Ring
8 Bottom Plate
9 Adjustment Screws
10 Screw Cyl
11 Screw Plug
12 Washer Fibre
Removing Impeller.
Remove screws (10).
 Remove bottom plate (8).
Remove screw (6).
Remove washer (5).
 Remove impeller (4) using impeller pullers.
Refitting Impeller.
 Add grease to the shaft.
Fit screws (10).
Bottom plate.
 Fit bottom plate (8) into volute (1) until there
is contact to the impeller (4).
Rotate adjusting screws (9) clockwise until
 there is light contact with the volute (1).
Rotate another half turn clockwise.
Secure screws (10) tightly.
 Check that impeller (4) rotates freely.

Workshop Manual
4.4 Wet End Piranha Hydraulics
 1 Volute
2 Mechanical Seal
3 Impeller
4 Screw Cyl
5 O-Ring
6 Bottom Plate
7 Gasket
8 Shredding Ring
9 Adjustment Screws
 10 Screw Cyl
 11
12
Circlip
Roll Pin
13 Shredding Rotor
14 Screw Slot
Removing Impeller
Remove screws (10).
 Remove bottom plate (6).
Remove screw (4).
Remove shredding rotor (13).
 Remove impeller (3) with impeller pullers.
Refitting Impeller
  Add grease to shaft.
Fit shredding rotor (13) to impeller (3) and
fix with screw (4).
 Remove shredding ring (8) from bottom
plate (6).
Fit bottom plate (6) into the volute (1) until
 there is contact with the impeller (3).
Rotate the adjusting screws (9) clockwise
until there is light contact to the volute (1).
Rotate the adjusting screws (9) another full
turn clockwise.
Fit screws (10) and tighten.
Check free rotating of impeller (3) by
rotating the shredding rotor (13) by hand.
Fit the shredding ring (8) with screws (14).
Check that there is no contact between the
 shredding rotor (13) and shredding ring (8).
 

10 Workshop Manual
4.5 Wet End RW Hydraulics

1 Oil Chamber
2 Mechanical Seal
3 Circlip
4 Propeller
 5 Washer
6 Screw Cyl
7 SD Ring
8 Band
9 Clamp

Removing Propeller
Remove screw (6).
Remove washer (5).
 Remove propeller (4) using pullers.
Refitting Propeller
Add grease to shaft.
Fit propeller (4) to shaft.
Fit sd ring (7) over propeller (4).
 Fit washer (5) and screw (6).
Removing SD Ring
Remove propeller (4).
Remove band (8).
Remove sd ring (7).

Refitting SD Ring
Fit sd ring (7) to oil chamber (1).
 Fit propeller (4) to shaft.
Fit sd ring (7) over propeller (4).


Workshop Manual 11
5 Oil Filling and Oil Change
Oil Draining
Remove screw (1) and sealing washer (2).
Place Pump in a Horizontal position with
plug hole at the bottom
Oil Filling
Place pump into Horizontal position with
the plug hole to the top.
Slowly fill oil into fill hole.
Select the required volume from the oil
filling quantities sheet.
Refit screw (1) and sealing washer (2).
m
Oil white ISO VG15 FP175C (eg. Finol DH 3017 -1, ESSO Marcol 82)
PUMP TYPE LITRES

0530 0.57
0630 0.56
0830 0.56
0840 0.48
1030 0.56
PIRANHA 0.53
RW 0.47
12 Workshop Manual
6 Mechanical Seal - Removal & Refitting
Primary Seal Note

Before removal of the mechanical seal or cartridge
seal:
Drain oil.
 Remove impeller.
Primary Seal
Removal
Remove circlip (3).
Slide mechanical seal (2) carefully from shaft.
Refitting
Only refit seals that are not visibly damaged.
Clean shaft and sealing area for static ring with
 soapy water.
Lubricate the rubber boot on the static ring with
soapy water.
Slide on the shaft and press into the volute (1) with
 insertion tool.
Lubricate the rotating part of the seal with soapy
water.
Slide the seal onto the shaft with the nylon
 insertion tool (see page 18).
Secure into position with circlip (3).
Secondary Seal
Removal
Secondary Seal Remove the primary seal.
 Mark the position of the volute relative to the
motorhousing.
Remove the volute.
  Remove circlip (4).
Slide mechanical seal (3) carefully from shaft.
Refitting
 Only refit seals that are not visibly damaged.
Fit support washer (2) into bearing lid (1).
Clean shaft and sealing area for static ring with
 soapy water.
Lubricate the rubber boot on the static ring with
 soapy water.
Slide on the shaft and press into the bearing lid (1)
 with insertion tool.
Lubricate the rotating part of the seal with soapy
water.
Slide the seal onto the shaft with the Nylon
Insertion tool (see page 19).
 Secure into position with circlip (4).
m
Ensure work area and tools are clean.
Workshop Manual 13
7 Motor Cable & Cable Cap connection - Stator Removal
 Cable and Cable Cap

Removal of Cable
Mark position of motor housing relative to the volute.
Remove screws (12).
 Wedge a screwdriver behind the impeller through the
 volute outlet.
Using a hoist lift, rise the motorhousing 50mm.
Disconnect the DI probe from the bearing lid.
Remove the motor housing (6).
 Cut the cable leads at the butt connectors (11).
Unscrew earth connection (9).
    Remove screws (1) from cable cap.
Pull cable (2) from motor housing.
Refitting of Cable
 Slide cable cap (2) on to cable.
Slide washer (3) on to cable.
    Fit seal (4) on to cable.
Place washer (5) into housing.
Refit the cable cap with screws (1).
Connect the cable leads to stator using new butt
connectors.
See wiring instruction in Operation and Instruction
Manual.
 Re-connect the earth connection and refit the DI.
Re-assemble the pump.
 Stator

Removal
The stator is held in by a compression fit only, so
 therefore it can only be removed by pulling it out by
force.
Remove cable and cable cap, also remove
 motorhousing from hydraulic section.
Pull stator out using stator extraction tools (see pages
22-23). It is not recommended to heat the housing as a
means of removing stator alone, but flash heating can
assist in stator removal.
Refitting
Refitting of stator can only be done by means of a
heavy press and insertion tool (see page 17).
A pressure of up to 10 tons must be applied for largest
size motor.
Motorhousing must be square when the stator is
pressed in.
Stator Puller Reference Table

Motor Part No Motor Part No
12/2 96995167 10/4 96995168
16/2 96995167 13/4 96995168
17/2 96995167 16/4 96995168
18/2 96995167 18/4 96995168
21/2 96995182 22/4 96995183
26/2 96995182 25/4 96995183
30/2 96995182 28/4 96995183
14 Workshop Manual
8 Rotor Shaft and Bearing removal
Upper Bearing

Removal
Remove motorhousing.
Remove bearing (1) using bearing pullers.
Refitting
Place bearing (1) onto shaft (2).
 Ensure bearing is perpindicular.
Press fully home.
Lower Bearing
Removal
Drain oil.
 Remove impeller.
Remove lower mechanical seal.
Remove upper mechanical seal or lip seal.
Remove motorhousing.
 Remove circlip (7).
Remove circlip (6).
Tap shaft (2) out of bearing lid (3).
 Remove bearing (5) from bearing lid (3).
Refitting
Place washer (4) into bearing lid (3).
Lubricate bearing (5) with grease.
Press bearing (5) into bearing lid (3) using insertion
tool (see page 25).
Refit circlip (7).
 Support bearing (5) with support tool (see page 26).
Press shaft (2) through bearing lid (3) and bearing
(5).
Refit circlip (6).
DI Probe
Non EX Version
Remove plug from probe (10).
Remove circlip (9).
 Remove probe (10).
European EX Version
Remove plug from probe.
 Remove probe.
American EX Version
 Unscrew probe from bearing lid.

Workshop Manual 15
9 Test Procedure
Air gap
When reassembling stator and rotor, the gap is set by the tolerances of the machined parts and is not
changeable.
High voltage test
A high voltage test is recommended if the pump has been repaired or reassembled. Link all power leads
together and apply a high voltage between earth and power leads. A voltage of 1,800 volts (= 2 x rated
voltage + 1000 volts) is used. This test should only last one second. This test will show any breakdown of
insulation.
Earth check
A earth check is recommended if the pump has been repaired or reassembled. This involves checking the
continuity between earth lead and the motorhousing ( where earth lead is connected). This can be done
with a resistance meter.
Pressure test
This is performed to check sealing of the unit and is recommended if the pump has been repaired or
reassembled. All pressure testing must be carried out without oil or coolant in the oil pump. Firstly drain the
oil or coolant.
NOTE It is absolutely essential the testing be carried out in the following manner to
prevent dislodging the lip seal in bearing lid.
Oil chamber connection
Remove pressure test screw (1) and washer (2) from oil chamber (see page 11). Screw pressure test probe,
with sealing ring, into test hole and apply pressure of ½ bar (7 psi) - not to be exceeded. This process
will check the sealing of outer mechanical seal, sealing between oil chamber and motorhousing, and the
cooling jacket if fitted.
Motor connection
Remove pressure test screw (30) with sealing ring (29) and in the case of EX version seal washer (31) (see
page 11). Screw pressure test probe with sealing ring into test hole and apply pressure of ½ bar (7 psi).
- not to be exceeded. This process will check the sealing of the motor chamber i.e. cable entry and sealing
into oil chamber.
Pressure test
Lower into water. Leave motor submerged for a few minutes, to allow trapped air to excape, and observe
any leaks, which are indicated by a flow of bubbles.
Raise pump from water and disconnect pressure from motorhousing first and then oil chamber.
Additional test
The sealing between oil chamber and motorhousing (Mechanical/lip seal & DI probe) can be checked by
applying pressure to oil chamber as above, and connect an U-tube to the motorhousing through the test
hole, to detect pressure difference in motorhousing. The U-tube should contain a small quantity of water in
the bend, if it displaces then there is a leak from the oil chamber.
Run test
A dry run test should be run to check the amps, voltage, and power drawn against rated data. See
instruction booklet for table of rated data. If this dry test is run without oil in the oil chamber it should only be
run for 20 seconds maximum otherwise damage could occur to the mechanical seal.
16 Workshop Manual
10 Troubleshooting Tips
Test Possible Fault Action
1 Visual check Damaged power cable. High voltage & Ohms test before replacing
Impeller jammed. Inspect and remove jammed object.
2 High voltage Water inside motor. Replace stator.
test failure Stator insulation damaged. Replace power cable.
Power cable or lead damaged.
3 Ohms test Stator failure.

Water inside motor.
Problem Possible Cause Action
1 Water in oil Loose or damaged oil plug. Check plug - replace.

chamber
DI light switches on Mechanical seal failure. Replace mechanical seal.

(if connected)
2 Water inside Damaged lip seal or mechanical Replace seal.

motorhousing seal.
Damaged o-ring between oil Replace o-ring.
chamber and motorhousing.
Cut in power cable. Replace power cable.
Low head Incorrect rotation. Check rotation (see installion instructions)

3
Bottom plate gap to large. Adjust bottom plate gap.
4 Over heating Pump Impeller blockage. Remove impeller and clean

switching on/off around volute.
intermittently
Thermal protection - Pump running continuously Check float operation control

light switching on unsubmerged. panel.
(if connected).
Workshop Manual 17
11 Tool Drawings
11.1 Tool Drawings - Stator Insertion
Stator Insertion Tool

Drawing Number 96995195 / 5196
Material: MILD STEEL
Dimensions in mm
Untoleranced machined dimensions to DIN 7168 m
Motor B C D Tool No:

Small 117.5 105 99 96995195
Large 142 134 128 96994196
18 Workshop Manual
11.2 Tool Drawings - Mechanical Seal Insertion
Outer Mechanical Seal Press Tool Mechanical Seal Sleeve

Drawing Number: 96995193 Drawing Number: 96995194
Material: NYLON Material: MILD STEEL
Dimensions in mm Dimensions in mm
Untoleranced machined dimensions to DIN 7168 m Untoleranced machined dimensions to DIN 7168 m
Workshop Manual 19
11.2 Tool Drawings - Mechanical Seal Insertion
Inner Mechanical Seal Press Tool Inner Fixed Mechanical Seal Press Tool
Material: NYLON Material: NYLON
20 Workshop Manual
11.3 Tool Drawings - Lip Seal Insertion
Lip Seal Press Tool

Drawing Number: 96995189
Material: NYLON
Dimensions in mm
Workshop Manual 21
13.4 Tool Drawings - Pressure Test
Pressure Test Tool (Oil Chamber Connection)

Dimensions in mm
Pressure Test Tool (Motor Housing Connection)

Dimensions in mm
22 Workshop Manual
13.5 Tool Drawings - Stator Extraction
Stator Extraction Tool

Dimensions in mm
Workshop Manual 23
13.6 Tool Drawings - Stator Pullers

Material: MILD STEEL Material: MILD STEEL

Material: MILD STEEL Material: MILD STEEL
24 Workshop Manual
13.7 Tool Drawings - Impeller Pullers
Piranha Impeller Pullers

Dimensions in mm
CB Impeller Pullers
Dimensions in mm
Workshop Manual 25
13.8 Tool Drawings - Bearing Press
Lower Bearing Press Tool

Drawing Number: 96995192 / 5201
Dimensions in mm
Motor A Part No.

Small 19.5 96995192
Large 24.5 96995201
26 Workshop Manual
13.9 Tool Drawings - Bearing Support
Lower Bearing Support Tool

Drawing Number: 96995202 / 5203
Dimensions in mm
Motor A B Part No.

Small 21 28 96995202
Large 26 35 96995203
ABS Production Wexford Ltd., Clonard Road, Wexford, Ireland
Tel. +353 53 91 63 200 Fax +353 53 91 42335. www.absgroup.com

Work Shop ABS AFP

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ABS submersible sewage pump AS

ABS submersible mixer pump RW

ABS submersible sewage pump AS

ABS Piranha submersible grinder pump

ABS reserves the right to alter specifications due to technical developments

1 Health and Safety Instructions

Observe all accident prevention measures and regulations!

ATTENTION Repair on explosion-proof motors may only be carried out by workshops or

2.1 Dimensions and Weights

2.2 Tightening Torques

In case of screwed conections, using “Nord-Lock” securing washers

4.1 Wet End AS / Vortex Impeller

4.2 Wet End AS / CB Impeller

4.3 Wet End AS / CB Impeller

4.4 Wet End Piranha Hydraulics

4.5 Wet End RW Hydraulics

5 Oil Filling and Oil Change

PUMP TYPE LITRES

6 Mechanical Seal - Removal & Refitting

Primary Seal Note

7 Motor Cable & Cable Cap connection - Stator Removal

 Cable and Cable Cap

Stator Puller Reference Table

8 Rotor Shaft and Bearing removal

Test Possible Fault Action

3 Ohms test Stator failure.

Problem Possible Cause Action

1 Water in oil Loose or damaged oil plug. Check plug - replace.

DI light switches on Mechanical seal failure. Replace mechanical seal.

2 Water inside Damaged lip seal or mechanical Replace seal.

Low head Incorrect rotation. Check rotation (see installion instructions)

4 Over heating Pump Impeller blockage. Remove impeller and clean

Thermal protection - Pump running continuously Check float operation control

11.1 Tool Drawings - Stator Insertion

Stator Insertion Tool

Motor B C D Tool No:

11.2 Tool Drawings - Mechanical Seal Insertion

Outer Mechanical Seal Press Tool Mechanical Seal Sleeve

11.2 Tool Drawings - Mechanical Seal Insertion

11.3 Tool Drawings - Lip Seal Insertion

Lip Seal Press Tool

13.4 Tool Drawings - Pressure Test

Pressure Test Tool (Oil Chamber Connection)

Pressure Test Tool (Motor Housing Connection)

13.5 Tool Drawings - Stator Extraction

Stator Extraction Tool

13.6 Tool Drawings - Stator Pullers

Drawing Number: 96995182 Drawing Number: 96995183

13.7 Tool Drawings - Impeller Pullers

Piranha Impeller Pullers

13.8 Tool Drawings - Bearing Press

Lower Bearing Press Tool

Motor A Part No.

13.9 Tool Drawings - Bearing Support

Lower Bearing Support Tool

Motor A B Part No.

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