Doc.no.

: FFS-625
Written by: RS
Rev. 00 / 08.04.2016
Page 1 of 8

Clutch disc replacement Instruction

FFS SFP 250x350XPC, SFP 300x400XPC
Pump Unit

Document no. : FFS – 349 Document control

Version Description Written Approved Date
by
00 First Release RS TN 08.04.2016

Contents
1 GENERAL DESCRIPTION 2
1.1 Safety precautions 2
1.2 Reference drawings and documentation 2
1.3 Needed tools and chemicals 2
2 PREPARATION 3
3 DISMANTLING FROM FOUNDATION 3
4 DISMOUNT PUMP CASING 4
5 DISMANTLING /ASSEMBLY TRANSMISSION 5
6 ASSEMBLY CLUTCH AND SHAFT 7
7 CLOSE CASING 8

Fire Fighting Systems AS Tel: +47 69 24 49 90

Box 369 Fax: +47 69 24 49 95
N-1502 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com
 Doc.no.: FFS-625
Written by: RS
Rev. 00 / 08.04.2016
Page 2 of 8

1 GENERAL DESCRIPTION

• This document is made for use for clutch replacement of the SFP-XPC pump units
designed by FFS AS.
• The installation and assembly must be performed by qualified personnel. The directives
given in this manual must be followed closely.

1.1 Safety precautions

• Only use approved and certified lifting gear for performing lifting operations.
• Do not under any circumstance heat roller bearings to temperatures above 100 deg C.
• When using Loctite or other chemical in assembly, excess after mounting must be
removed in order to prevent later contamination of hydraulic oil.
• Use only clean rags and lint-free paper towels. Cleanliness during assembly is of vital
importance, in order to prevent clogging of hydraulic components.
• Store and handle all hydraulic components with care and in a clean environment.
Inspection
• Inspect the parts carefully for any signs of transport damage or other deviations which
may have occurred during transport.
• Make sure that all equipment and parts are available.
• Clean all parts to have future contact with hydraulic oil thoroughly with suitable solvent
before assembly.

1.2 Reference drawings and documentation

• 618A-21 (Sheets 1, 3 and 4) – Assembly Drawing (SFP 250x350XP(C))
• 628A-2047, -21 - Assembly Drawing (SFP 300x400XP(C))
• 618A-2008 – Block (SFP 250x350XP(C)/SFP 300x400XP(C))
• 618A-21-H1 – Hydraulic diagram (SFP 250x350XP(C)/SFP 300x400XP(C))
• 618A/628A -2039 – Shaft Assembly (SFP 250x350XPC/SFP 300x400XPC)

1.3 Needed tools and chemicals

• Common metric spanners, socket wrench, torque wrench typ 20-210Nm and Allen keys
• Loctite 577 or equivalent – referred to as -L577
• Loctite 243 or equivalent – referred to as -L243
• Loctite 641 or equivalent – referred to as -L641
• Molykote 111 or equivalent silicon grease – referred to as -M111
• Common industrial grease for machinery – referred to as –GR
• Common acetone or paint thinner for metal parts degreasing
• OKS-200 Assembly paste for shaft connections –OKS

Fire Fighting Systems AS Tel: +47 69 24 49 90

Box 369 Fax: +47 69 24 49 95
N-1502 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com
 Doc.no.: FFS-625
Written by: RS
Rev. 00 / 08.04.2016
Page 3 of 8

2 Preparation
1) Open hatch cover located above the Hydraulic Block and inspect clutch condition inside
casing. Check if clutch discs are free or stucked (welded) together. Check if clutch housing
is dark/blue coloured due to overheating. If not coloured, clutch disc replacement should
not be neccesary

a. If discs are free, but housing dark/blue colorized: This tells the clutch has slipped,
but if the slipping time is limited it still may be possibility the discs are not
damaged. Reason for slipping may be related to low hydraulic pressure whch can
be:
i. Low Oil quantity (alarm Clutch pressure)
ii. Damaged oil pump (alarm Clutch pressure)
iii. Suction problem for oil pump (alarm Clutch pressure)
iv. Faulty Pressure valve (alarm Clutch pressure)
v. Too much Throttling of clutch engagement by valve located behind Clutch
pressure gauge (alarm Clutch pressure may not activate)
vi. Leakage in piping for clutch oil supply from hydraulic block
vii. Worn oil supply ring (alarm Clutch pressure may not activate)
b. If discs are stucked (welded: This tells the clutch has slipped and maust be
replaced/overhauled. Reason for slipping is same as explaned in 2a.

2) Ensure pump has not been overloaded.

a. Operation with overcapacity outside dutypoint
b. Foreign material stucked in impeller
c. High flange forces generate heavy pump wear ring contact
d. Alignment within specification.

3 Dismantling from foundation

1) Drain the unit of oil
2) Check alignment for flexible coupling
3) Split the flexible coupling
4) Disconnect Suction pipe and Discharge pipe. Observe no flange forces
5) Disconnect electric connection. Make sure power is switched off in FiFi control cabinet to
avoit short surquit and risk for damage PLC components.
6) Loosen unit from foundation. Check no bolt stress have been present when loosing by use
of blade gauge to measure no clearance under each foundation foot. (Not relevant for
Chock fast grouted installation)

Fire Fighting Systems AS Tel: +47 69 24 49 90

Box 369 Fax: +47 69 24 49 95
N-1502 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com
 Doc.no.: FFS-625
Written by: RS
Rev. 00 / 08.04.2016
Page 4 of 8

4 Dismount pump casing

1) Turn transmission pump unit with pump casing upwards. Support Casing on input side
face with input shaft/flange hanging free.
2) Remove nuts w/washer holding pump casing, item 10,11
3) Lift off the pump casing, item 1
4) Remove impeller end cap w/screw, item 8,9
5) Jack off pump impeller. It is possible to use 2xM20 holes at pcd180mm, but normally it is
possible to easy and carefully jack it from impeller backside.
6) Remove the impeller shaft key
7) Protect the shaft with tape to avoid scratching the shaft seal (Lip seal)
8) Notice the Lip seal behind the impeller which is to be very carefully handled when casing
cover is removed (item 17).
9) Remove the oil cooler (if applilcable) by dismantle 3x M10 socket screws to pump cover,
and 4x M8 Hex head screws to casing. Then Cooler can be pulled out horizontally.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Box 369 Fax: +47 69 24 49 95
N-1502 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com
 Doc.no.: FFS-625
Written by: RS
Rev. 00 / 08.04.2016
Page 5 of 8

5 Dismantling /assembly transmission

Split transmission Casing/Cover:

-Remove bolts item 29
-Remove 2x bolts item 37
-By access through the Hydraulic block
opening, disconnect the clutch pipe to the
Oil Supply ring and split the lube-oil
piping connected to the opposite side of
Oil Supply Ring (pos 8 in shaft assembly
drawing below).
-Use 4off M10 threads in cover to
splitting Cover from Casing

Use attention and care to the shaft sealing

(Lip seal) when this is intended to be
reused.

Lift bearing cover and ouput shaft with

clutch will follow. Put attention to the
splitted Lube oil pipe connected to the
Oil Supply ring in the pichture to the
Right

Secure the shat from dropping down

and loosen the Bearing Support
Marked out in Red in “Clutch shaft
assembly”drawing below.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Box 369 Fax: +47 69 24 49 95
N-1502 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com
 Doc.no.: FFS-625
Written by: RS
Rev. 00 / 08.04.2016
Page 6 of 8

Pichture shows iput shaft with clutch outer

housing left after the Cover with ouput shaft is
removed. Pichture shows also the one end of
lube oil piping which has to be splitted before
Cover and output shaft can be lifted out (ref.
explained in previous picture)

Clutch Shaft assembly:

Ref picture above:

• Dismantle Seal sleeve w/o-rings, (item 4, 5). This is loose and easy to pull off by hand.
• Pull off Bearing, (item 20), by means of long M8 threads to “Bearing Support Ring”.Use
some heat warm up the bearing 70-80 degree simultanously with pulling the bearing.
Make sure no spots in bearings are overheated if re-use of bearing is intended.
• Oil Supply ring (item 8) can easy be pulled off by hand. Measurement between shaft and
Oil upply ring should be reccorded by blade feeler gauge

Fire Fighting Systems AS Tel: +47 69 24 49 90

Box 369 Fax: +47 69 24 49 95
N-1502 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com
 Doc.no.: FFS-625
Written by: RS
Rev. 00 / 08.04.2016
Page 7 of 8

Clutch assembly (half section view):

Ref picture above:

• Dismantle the Socket screw bolts (item 16). Put attention to some spring force, but the
bolts are long enough to fully release the springforce and the pressure plate can easy be
removed.
• Remove the Disc-package and springs (item 18, 19)
• Push the Cylinder housing (item 3) appr, 5mm to the right for access to remove the lock
ring (item 15)
• Pull off the Cylinder housing (item 3) and Piston (item 2) by hand for access to the
Sealings (item 10, 11, 13)

6 Assembly Clutch and shaft

Ref pichture Clutch assembly (half section view):

• Clean remaining clutch components before re-assemly
• Apply Litium grease alternative (alternative oil) and fit Sealings (item 10, 11, 13)
• Install Piston (item 2) and Piston Housing (item 3) and fit the Lock ring (item 15)
• Install the clutch discs. Put attention to correct installation of discs, every second outer-
inner-outer disc. First and last disc is outer disc (Outer disc has teeth outside)
• Install clutch pressure plate and fit the Bolts (item 16) in cross section with thightening
torque 69Nm.

Ref pichture Clutch shaft assembly (half section view):

• Install preferably new Oil Supply ring (itm 8). Alternative measure diametric clearance
between shaft and Oil Supply ring max 0,10mm.
• Fit the thin spacer ring (item 18, observe correct orientation with inside chamfer towards
shaft radius)
• Heat Ball bearing (item 20), ensure the Bearing Support Ring is inside with correct
orientation and fit the Ball bearing with bushing Loctite 641.
• Fit Sleeve with O-rings (item 4, 5)
• Install the shaft assembly in reverse order as dis-assembly.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Box 369 Fax: +47 69 24 49 95
N-1502 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com
 Doc.no.: FFS-625
Written by: RS
Rev. 00 / 08.04.2016
Page 8 of 8

7 CLOSE CASING
Apply silicone seal on Transmission Casing’s mating surfaces – be sure to cover the whole
surface with suitable brush. Apply the fibre Gasket casing 250XPC:618A-1172-A,
300XPC:4000244

Put attention and take care with shaft sealing (simmering and Lip Seal). Apply grease to protect
and for safe assembly.

(
Lift Pump Cover onto Transmission Casing in correct position. Ensure 2pcs Guide pinns are not
jet fitted. They are to be fitted when there is a gap of 3-5mm between “Casing” and “Pump cover”
to align before mating togheter.

Fit the “Socket Screws” for the “Pump Cover” and tightening to torque 50Nm in sequence. When
complete, retighten for checking all bolts are with corret torque. Also re-tight 50Nm in sequience
after approx. 10hours settling time (can be done after installed back, just before test-run)

Fit impeller with key and shaft-end cap (OKS). Apply Loctite 243 on the M10 bolt and tightening
torque 50Nm

Install Pump casing. Ensure the big O-ring is without damage and applied with grease for smooth
engagement. Ensure O-ring groove and mating counter surface is clean and smooth.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Box 369 Fax: +47 69 24 49 95
N-1502 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com