Johnson Controls Disassembly and Assembly AS-series, General instructions, Rings and lip seals

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11.0Disassembly and Assembly AS-series

11.1General instructions

Assembly and disassembly may be preformed by qualified personnel only. Always wear appropriate safety clothing. Make sure that personnel are instructed and educated.

Insufficient or wrong assembly and disassembly can lead to the pump malfunction. Johnson Pump is not liable for accidents and/or damage caused by non-compliance with the guidelines.

Always work in a clean surrounding. Keep all highly sensitive parts such as seals, O- rings, bearings, etc. in their original packing as long as possible.

Use a clean work surface.

Check that the parts to be used have not been damaged during transport.

Never work on the pump in operation. In case of a disassembled pump, avoid any contact with the impeller when turning the shaft manually.

Do not forget that the pump can be started even when the pump casing has been remo- ved for e.g. cleaning. Never run the pump without the pump casing. Follow the instructions for shutdown before performing any maintenance or service.

After disassembly carefully clean the parts and check them for damage, especially the mounting surfaces, and replace all damaged parts.

All parts fitted together at the disassembly must stay together when reinstalled, especially the impeller, shaft, shim and back plate.

11.2O-rings and lip seals

When working with lip seals or O-rings, take care not to damage them as they pass over sharp edges of splines, threads, etc. Be sure that the O-rings are not twisted in the groove when installing.

All O-rings and sealing lips should be lubricated with a suitable lubricant before fitting, e.g. soap and water or silicone spray.

For O-rings made of PTFE, it is advised to heat them up in hot water before placement. A warmed up O-ring becomes softer, thus easier to install. Be aware of that PTFE has no thermal memory.

11.3Shutdown

Before starting the maintenance or inspection, follow the next steps to shut down the pump.

1.Stop the pump. To prevent the motor from starting while you are working on the pump follow the procedure below:

•Turn off the pump at the electrical cabinet.

•Set the pump circuit breaker to off.

•Switch off and lock the operating switch.

•Remove the fuse.

•Sign the electrical cabinet “danger”.

2.Remove, if necessary, the protection around the shaft coupling when the pump has stopped completely.

3.Let the pump cool down to ambient temperature.

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IM-AS/02.00 GB (0412)

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Contents TopClean AS CE Declaration of conformity Index 14.0 Trouble shooting chart 15.0 Disposal of the pump Symbols Safety warnings IntroductionTransportation, receipt and transferring of goods TransportationReceipt TransferringDescription Sound pressure levelInstallation Non-permitted usesSuction and inflow conditions PipingOperation Electrical connectionPreliminary operations and starting Cleaning the pump Spare partsOperating checks Extended stopSeals Disassembly and Assembly AS-series General instructionsRings and lip seals ShutdownDisassembly Removal of pump casing and impeller AS 40, 50, 60, 65Removal of pump casing and impeller AS 42 and AS Seal disassembly ExecutionAssembly Bearing removalClearances Pump assembly AS 40, 50, 60 Seal assemblyExecution Pump cover and Impeller assembly AS 42 and AS Spare parts lists and sectional drawings Spare part list AS 40, 50, 60-6512.2 AS 40 Execution T, Q 12.3 AS 50 Execution T, Q 12.4 AS 60-65 Execution T, Q 12.5 AS 80 Execution T, Q Spare part list AS 42 Pos Denomination Material12.7 AS 42 Execution T, Q 12.8 AS 52 Execution T, Q Dimensions and weights 13.1 AS 40-50-60-65-80 with shroud 1450 rpm13.2 AS 40-50-60-65-80 without shroud 1450 rpm 13.3 AS 42-52 with shroud 1450 rpm 13.4 AS 42-52 with shroud 1450 rpmTrouble shooting chart Pump does not primeDisposal of the pump Johnson Pump Industry Group

AS specifications

Johnson Controls AS is a leading global company that specializes in automotive batteries and advanced automotive technologies. With a rich history spanning over 130 years, it has become a vital player in the automotive supply industry. Headquartered in Cork, Ireland, Johnson Controls operates in more than 150 countries, serving a wide array of clients from automotive original equipment manufacturers (OEMs) to aftermarket retailers.

One of the main features of Johnson Controls AS is its strong focus on sustainability and energy efficiency. The company has made significant investments in research and development to create advanced battery technologies that not only enhance performance but also reduce environmental impact. Their commitment to sustainability is reflected in their efforts to develop eco-friendly battery solutions, such as lithium-ion and other renewable technologies, which aim to lower carbon footprints in the automotive sector.

In the realm of technology, Johnson Controls AS is at the forefront of battery innovation. Their products include lead-acid batteries, lithium-ion batteries, and advanced AGM (Absorbent Glass Mat) batteries. These technologies are designed to meet the increasing demands for power and efficiency in modern vehicles, especially those with extensive electronic systems and electric powertrains. The lithium-ion batteries they produce are crucial for electric and hybrid vehicles, offering high energy density, lighter weight, and longer life cycles compared to traditional batteries.

Another characteristic that distinguishes Johnson Controls AS is its integrated approach to energy management. The company not only produces batteries but also offers comprehensive solutions that encompass energy storage systems, power management, and smart grid technologies. This holistic view allows them to provide customized solutions for various applications, from automotive to stationary energy storage systems.

Quality and reliability are core principles at Johnson Controls AS. The company employs rigorous testing and quality control processes to ensure their products meet the highest standards. With a strong emphasis on innovation, customer service, and sustainability, Johnson Controls AS continues to lead the charge in providing cutting-edge solutions in the evolving automotive landscape. As the industry shifts toward greater electrification and renewable energy sources, Johnson Controls is well-positioned to remain a key player in the market, driving advancements that support both automotive performance and environmental stewardship.
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