SUNDYNE LMV-311 PUMPS

Instruction and Operation Manual March 2005

14845 W. 64th Avenue • Arvada, Colorado 80007 USA • +1-303-425-0800 • FAX: +1-303-425-0896 • www.sundyne.com Sundyne Europe • Longvic Cedex • France • 33-3-80-383300 • FAX: 33-3-80-383371 ANSIMAG • ANYSPEED • CASTER • GSP • HMD/KONTRO • MASO/SINE • SCMP • COMPRESSORS • SUNDYNE • SUNFLO

Copyright
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior permission of Sundyne Corporation. © 2005 Sundyne Corporation

Warranty
Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the date of being placed in service (but not to exceed eighteen (18) months after the date of shipment) that the equipment at the time of shipment will be free from defects of design, material and workmanship. If any defects or malperformance occur during the warranty period, Sundyne’s sole obligation shall be limited to alteration, repair or replacement at Sundyne’s expense, F.O.B. Factory, of parts or equipment, which upon return to Sundyne and upon Sundyne’s examination prove to be defective. Equipment and accessories not manufactured by Sundyne are warranted only to the extent of and by the original manufacturers’ warranty. Sundyne shall not be liable for damage or wear to equipment caused by abnormal conditions, vibration, failure to properly prime or to operate equipment without flow or caused by corrosives, abrasives or foreign objects. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no event shall Sundyne be liable for consequential or incidental damages

14845 W. 64th Avenue • Arvada, Colorado 80007 USA • +1-303-425-0800 • FAX: +1-303-425-0896 • www.sundyne.com Sundyne Europe • Longvic Cedex • France • 33-3-80-383300 • FAX: 33-3-80-383371 ANSIMAG • ANYSPEED • CASTER • GSP • HMD/KONTRO • MASO/SINE • SCMP • COMPRESSORS • SUNDYNE • SUNFLO

Contents
Contents.............................................. ii INTRODUCTION.................................. 1 Sundyne Centrifugal Pumps ............... 1 Text Symbols........................................... 1 Equipment and Safety Precautions .. 1 Wearing Personal Protective Equipment) ............................................ 2 Using Forklifts ....................................... 2 Ensuring Electrical Safety ................... 2 Testing Equipment ............................... 2 Using Chemicals .................................. 2 Protection from Falling ........................ 2 Preventative Machine Guards............ 2 Explosion/Fire Hazard ......................... 3 Pre-Commission Checklist.................. 3 Familiarizing Yourself with the Pump 3 Driver Instructions ................................ 3 Verifying Auxiliaries.............................. 3 Installing a Seal Environmental Control System ..................................... 3 Checking Driver Rotation .................... 3 Piping Connections .............................. 3 Start-Up Checklist.................................. 4 Pressurizing the Fluid Loop ................ 4 Servicing the Gearbox ......................... 4 Auxiliary Lube Pump............................ 4 Setting the Valves ................................ 4 Control Checklist ................................... 4 Verifying Operating Conditions .......... 4 Adjusting the Cooling Flow ................. 4 Installation and Start-Up Checklist ... 5 INSTALLATION ................................... 7 Inspection................................................. 7
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Storing Your Pump Short-Term ......... 7 Storing Your Pump Long-Term .......... 7 Suction and Discharge Piping............ 8 Seal Environmental Control System. 9 Liquid Buffer System ............................ 9 Mounting Vertical Units Without Stands ....................................................... 9 Mounting Vertical Units with Stands (LMV) ....................................................... 10 Base Mounted (BMP) Units ............... 10 Driver and Coupling ............................ 10 Flexible Coupling for LMV Units Without a Vertical Stand..................... 11 LUBE SYSTEM.................................. 12 Lube System.......................................... 12 Gearbox Heat Exchanger ................... 12 Oil Manifolds ....................................... 12 Remote Heat Exchanger................... 13 Gearbox Sump ...................................... 13 SundGard® Oil Filter............................ 13 Main Lube Pump and Lube Oil Priming Kit ............................................. 14 Oil Pressure ........................................... 14 START UP ......................................... 15 Start-Up Procedures............................ 15

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................. 53 Falk Steelflex Type Coupling Specifications ....... 47 TROUBLESHOOTING.......... 72 Sundyne Corporation iii http://www.... 66 Separator Arrangements............................................................................. 17 Parallel Operation......................... 17 System Head Curve............................................. 16 Parallel Operation............... 69 Pump Casing and Seal Housing (Exploded View). 49 Gearbox & Pump Diagnostics ....... 19 Disassembly of LMV-311................................. Cleaning and Repair.................................. 57 Gearbox Replacement Parts ..... 54 Thomas Type DBZ Coupling Specifications ............................................. 16 OPERATION & CONTROL............... 63 Double Seal Arrangement and Parts .............................................................................com ...... 17 Operation of Sundyne Pumps ... 31 Shaft Sleeve............. 62 Pumps Parts List.... 64 Single Seal Arrangement and Parts 65 Tandem Seal Arrangement and Parts ......................................................................................... 17 Minimum Flow Conditions...................................................... 60 Pump Disassembly Replacement Parts................sundyne................... 31 Inspecting All Bearings. 18 MAINTENANCE.... 54 Thomas SN Spacer Type Vertical & Horizontal Coupling Specifications 55 Gearbox Lube Oil Specifications.......................................... 32 Bearing and Shaft Clearances............... 67 Pump and Gearbox Cross Section (Single Seal Arrangement).. 59 Mechanical Seals .........Controlling the Pump During Startup ......................................... 53 Falk Double Gear Type Coupling Specifications ....................................................... 17 Entrained Gases............. 56 Gearbox Parts List .......... 68 LMV-311 Gearbox (Exploded View)............................................................................ 17 Suction Conditions .......... 33 Procedure for Checking the HighSpeed Shaft Endplay........................................................ 31 Gearbox Mechanical Seal..... 49 Pump Mechanical Seal Diagnostics 51 SPECIFICATIONS ........... 71 INDEX ................................. 31 High-Speed Shaft ................... 16 Single Operation........................ 58 Gearbox and Pump Torque Values ................................ 53 Falk Double Gear Type-Vertical Specifications ................ 70 Gaskets ..... 32 Reassembly of the LMV-311...................................... 19 Inspection...............................................................................

RECOMMENDED: Text accompanied by this symbol indicates recommended usage. Commonly applied in refineries. install or use authorized Sundyne pump parts and accessories is considered misuse and damage or failure caused by misuse is not covered by Sundyne’s warranty. and power generation plants. Designed to increase the pressure of a continuous flow of fluid by applying centrifugal action. Failure to properly select. and Boiler Feed applications. 1 . servicing. CPI. Sundyne pumps are used in high-head. Sundyne cannot test all parts and accessories sourced from other vendors. REMINDER: Text accompanied by this symbol indicates a reminder to perform an action. modification of Sundyne products or removal of original components may impair the safety of these products and their effective operation. This manual presents installation.Instruction and Operation Manual INTRODUCTION Sundyne Centrifugal Pumps Sundyne pumps provide high-energy performance and competitive efficiencies in an industrial quality. compact unit that is simple to maintain. incorrect design and/or fabrication of such parts and accessories may adversely affect the performance and safety features of these products. Text Symbols The following symbols may be found in the text of this guide. Additionally. low-to-medium flow processes. Equipment and Safety Precautions Sundyne Corporation manufactures centrifugal pumps to exacting International Quality Management System Standards (ISO 9001) as certified and audited by Lloyd’s Register Quality Assurance Limited. Sundyne pumps are single stage that utilize an integral gearbox. Note: Parenthetical numbers included in the text correspond to item numbers on the illustrated figures. They have the following meanings: WARNING: Text accompanied by this symbol indicates that failure to follow directions could result in bodily harm or death. Genuine parts and accessories are specifically designed and tested for use with these products to ensure continued product quality and performance. ELECTRICAL HAZARD: Text accompanied by this symbol indicates that failure to follow directions could result in damage to equipment. Sundyne pumps are most commonly used in HPI. EQUIPMENT USE ALERT: Text accompanied by this symbol indicates that failure to follow directions could result in bodily harm or death. The correct spare part can be ordered for any generation pump by referencing the item and serial numbers. troubleshooting. maintenance and spare parts information for the latest configuration of Sundyne centrifugal pumps. petrochemical plants.

Locks or tags must be provided to warn employees that equipment is temporarily unavailable. safety glasses will not interfere with hearing protection seals. service or repair of equipment occurs. use chemical proof gloves. Be sure to clean all pieces of personal protective equipment immediately after each use. If applicable. Note: Follow company procedures prior to equipment testing at all times. Ensuring Electrical Safety All electrical sources must be powered-off before installation. Testing Equipment Prior to performing a test on newly installed. Preventative Machine Guards Preventative guards must remain in place on all equipment. Failure to follow safety precautions may lead to injury! Note: Sundyne recommends that a Lockout/Tag-out program be followed prior to altering the equipment. For example. maintained or repaired equipment.Instruction and Operation Manual Note: Safety procedures must be applied prior to any installation. Note: Before initializing forklift operation. maintenance. • Using Chemicals Any chemicals to be used must be accompanied by a relevant material safety data sheet (MSDS). the person installing the lock or tag must remove it according to company procedure. protective equipment must be worn at all times when installing. The following safety recommendations must be adhered to for optimum safety: • Safety glasses. all personnel in the immediate area must be warned. Note: Only remove the guards while performing maintenance or repair. Once all work has been completed. Note: Follow company fall prevention procedures prior to working on equipment. performing maintenance or repairing equipment. in accordance with government legislation. Using Forklifts Any persons operating a forklift must have an active recognized operator license. If any hazardous or flammable chemicals pass through the equipment. Note: An eye wash station (or equivalent) should be available in the event of injury. or repair of a Sundyne pump.0) hour period. 2 . Replace the guards immediately after working on the equipment and prior to start up. must be worn at all times. Hearing protection is strongly recommended at all times when noise levels exceed 85 dB during an eight (8. a complete decontamination of the equipment is required. with the minimum requirement of side shields. verify that the lift is in a safe operating position. dust or mists. Note: A dust mask respirator must be worn if chemicals have warning labels regarding fumes. consider their compatibility. • Note: Chemical resistant gloves must be used if chemical use is required (refer to Using Chemicals for additional information). When using more than one piece of protective equipment. Protection from Falling Fall protection and associated preventative measures is required when working on equipment located six feet or higher from the ground. Steel-toed shoes must be worn when lifting equipment greater than 15 pounds (7 kg) or if pallet jacks or forklifts are operated. Wearing Personal Protective Equipment) To ensure safety.

Piping Connections Verify that the following bolted or threaded connections are tight: • • • • • Pump flange bolts Seal environment piping and port connections Cooling water connections to heat exchanger (if applicable) Gearbox oil drain plug Pump case drain plug Verifying Auxiliaries Before start up. If required. check the direction of the motor fan. as indicated in the detailed specifications Verify all switch and instrument connections Verify that all switch and instrument settings are set to normal operating standards • • 3 . contact Sundyne Corporation. Familiarize yourself with the pump configuration before starting and operating the pump. and pressure meters. ampere meters. carefully review all information on the product. Installing a Seal Environmental Control System Install a system to control the seal environment. including: • • • • • • Specification sheets Outline drawings Performance curves Instruction and related manuals System P&ID/Process Flow Diagram (Clients equipment) Control system and operational philosophy/narrative (Client) • Calibrate all measurement equipment.Instruction and Operation Manual Explosion/Fire Hazard Note: Never use an acetylene torch or open flame to attempt to remove parts that have seized together in Sundyne equipment. etc. Pre-Commission Checklist Familiarizing Yourself with the Pump Before servicing and starting up the Sundyne pump. Driver Instructions Carefully follow all installation and starting instructions provided by the driver manufacturer. This information is included in the final data package. If the driver is splined. Any residual process gas or liquid that is flammable can result in an explosion or fire with potential for serious injury or death. install drain piping overhead to ensure that the environment operates under normal conditions. Also. such as flow meters. For more information. verify that port 1 is properly vented. then verify that the direction of the driver rotates in the same direction as the arrow stamped or cast on the pump casing. un-couple. verify that the following auxiliaries are met: • • Check the utility connections Verify that the auxiliary piping conforms to Sundyne standards. Checking Driver Rotation If the driver is coupled.

Maximum recommended temperature is 180°F (82°C). Note: Sundyne recommends that gearbox lube oil be changed at least every six months. Setting the Valves To set the pump to the designated operating point. Control Checklist Verifying Operating Conditions Verify the following parameters against the specifications on the specification sheet: • • • • • • • • • Suction pressure Suction temperature Discharge pressure Total head Flow rate Power consumption Specific gravity Viscosity Net Positive Suction Head (NPSH) The status of these conditions will significantly alter performance of the pump if they are not in accordance with the specification sheet. 4 . the lube oil level will lower about a quarter inch more than when idle. Under normal operation. Servicing the Gearbox Fill the gearbox with lube oil up to a quarter inch (¼) or 6 mm from the top of the oil level sight glass. if applicable. Adjusting the Cooling Flow If your model pump includes an installed heat exchanger for the gearbox. prior to admitting fluid into the pump casing. verify that it conforms to acceptable lube oil specification standards. Refer to the SPECIFICATIONS section in this manual for more information. Check with your Sundyne representative if the operation conditions of your pump must run under different parameters than indicated by the specifications on the specification sheet. For requirement information about priming the lube oil system. adjust the cooling flow to keep the temperature of the gearbox sump at 140°-160°F (60°-71°C). Additionally bubbles will appear at the top of the sight glass. start the pump with the suction valve in the open position while throttling the discharge valve. unlock the electrical circuit and move it to the “hand” position. Auxiliary Lube Pump If your pump includes an auxiliary lubrication pump. Check for oil leaks and recheck the oil level.Instruction and Operation Manual Start-Up Checklist Pressurizing the Fluid Loop Pressurize the double seal buffer loop or external seal flush. refer to the start-up section in this manual. Note: Prior to using lube oil.

It is not necessary to align the coupling for run-out or flatness as this is controlled by the rabbet fits on the gearbox and coupling adaptor. and request “Sundyne Field Service”. the auxiliary lube pump should be running prior to and anytime the suction is pressurized. Please call with any questions or comments. You must read and follow: instruction manuals. including main driver. have you opened the suction valve fully and discharge throttled to allow design flow. suction temperature. heat exchanger.3 kg/cm2g). and related piping been filled with oil (primed)? Do process conditions. discharge header pressure. unlock the electrical circuit and start it in the “hand” position. typically 40-50% open? Check the control valve to be sure it is functional. Check suction pressure to be sure it agrees with the specification sheet. 5 . Has the oil filter. For splined connections. Check for oil leaks and recheck the oil level. auxiliary lubrication system and instrumentation before working on this equipment. Has the pump been vented through Port 6? Open both supply and return valves supplying cooling water to the gearbox heat exchanger. a splined shaft or a coupling. be sure the coupling gap is correct and bolting between coupling halves is tight. and flanges for leaks. specification sheets and curves for this equipment during installation.Instruction and Operation Manual Installation and Start-Up Checklist Note: Lock out all switch gears. Check with your representative or Sundyne Corporation if you must test on a different fluid than shown on the specification sheet. Note: A drip leg must be used if the Port 1 connection rises from the seal housing. and specific gravity agree with specification sheet information? DO NOT test the pump on water unless it is designed for water.6 liters). outline drawings. This instruction manual contains coupling set-up information. commissioning. It is recommended that the input shaft be rotated by hand prior to mounting the motor. Is the needle valve on the gearbox pressure gauge open? Removal of the vent plug below the fill/vent fitting will speed filling. If the process suction pressure exceeds 460 psig (32. the splined shaft must be lubricated with the supplied spline grease and the two o-rings installed prior to mounting the motor. Prior to starting the unit. Be sure to have the unit serial number that is imprinted on the gearbox nameplate. This checklist is NOT intended to be inclusive. Is all the information underlined above readily available? Are the following bolted/threaded connections tight? o o o o o Pump flange bolts? Seal environment piping and port connections? Cooling water connections to heat exchanger(s)(if applicable)? Gearbox oil drain plug? Pump case drain plug? There are two types of connections between the motor and gearbox. and operation. Your total satisfaction is our goal. Is a check valve installed in the discharge line? Is Port 1 open to atmosphere or piped to safety drain or flare or vent header? (Back pressure must not exceed 5 psig). suction pressure. If you have auxiliary lubrication pump. Are all other seal system ports identified and connected according to the outline drawings? Is gearbox filled to within ¼” (6. Inspect the case drain. If the unit has a coupling. ports.35mm) of the top of the sight glass with the approved oil and the breather fitting installed? Oil capacity is 7 quarts (6.

Do this several times until gearbox oil pressure gauge shows pressure. Does the discharge pressure agree with the specification sheet? If flow control is being used.Instruction and Operation Manual Unlock the main driver circuit and bump the motor. After commissioning. please call your representative or Sundyne Corporation. throttle the discharge valve immediately after start-up. adjust cooling water supply until the oil temperature is 140-160°F (60-71°C) on units equipped with heat exchangers. adjust the valve until flow agrees with the design value listed on the specification sheet.1-4. 6 . run motor for 1 second on. then start the main driver. bumping the motor is not required. Listen for any unusual noises or pressure fluctuations. Once the gearbox oil temperature has stabilized. Is rotation correct? Once rotation is verified. Oil pressure will be between 15-60 psig (1. Rotation is CCW as viewed from the top end of the motor. Maximum recommended temperature is 180°F (82°C). If pressure control is being used. 20 seconds off.2 kg/cm2g) depending on the type of bearings in the gearbox. Note: If you have any questions or concerns about these procedures or the information supplied.

and if rotation is “not smooth. all components must be inspected by an authorized Sundyne service engineer. which may have occurred during shipment.Instruction and Operation Manual INSTALLATION Inspection Immediately inspect your Sundyne product upon receipt of the equipment. are: • • • Humidity Temperature Surrounding chemicals Long-term storage methods must prevent damaging conditions from making contact with the internal components of the equipment. To ensure the original quality of the Sundyne pump after storage. additional precautions are required for long-term storage. Ensure that the shipping covers be kept securely in place. Storing Your Pump Short-Term If your Sundyne pump is not to be installed immediately. If the input shaft does turn freely. protect it from exposure to moisture and dust.” damage may have occurred during shipping. long-term storage conditions must be met to ensure minimum corrosion damage to the gearbox and fluid-end components. Check for any damage. Components that are not manufactured by Sundyne (except mechanical seals) must be inspected by its own manufacturer. If your Sundyne pump will not be operated for a period of time exceeding six months from the date of shipment. Sundyne does not guarantee the quality of equipment during and after the storage period. Note: Any inspection fees are the sole responsibility of the purchaser. Factors which affect the quality of a Sundyne pump. When the equipment is stored in strong chemical environments or near salt water. Storing Your Pump Long-Term In addition to the precautions in the short-term section above. Recommended Long-Term Storage Procedures Sundyne recommends that you do the following to prevent damage to your pump during longterm storage: 7 . Do not remove the factory installed shipping covers for casing flanges and seal ports. when stored. Note: The input shaft on the pump may not turn freely due to seal drag and speed increasing gear meshes. Note: Sundyne does not accept liability for equipment damaged during the storage period. Note: Observe the storage instructions provided by the driver manufacturer. Notify the carrier and Sundyne immediately if damage is evident. protection must occur immediately upon receipt of the equipment.

climate controlled building. This practice will minimize process leakage and prevent possible reverse rotation from pump back-flow. 3. It is recommended that suction and discharge pressure gauges be installed on any pump that is not flow controlled. When installing piping to the pump. 4. Use block valves (both suction and discharge) when isolating the pump during shutdown. Never use a suction pipe that is smaller in diameter than the pump suction inlet. Note: Never use force to position piping into place at the flanged suction and discharge connection locations. 8 . Note: Because long-term storage of equipment is of a highly critical nature. 5. 3. Failure to have piping properly aligned may impose excessive strains on the unit. it is recommended that Sundyne be contacted to provide more details on the above procedures. 4. Note: Carefully select the size of pipe and fittings to be installed so that friction losses will remain low. This procedure will protect the impeller from damage by mill scale. 6. Install a suction (35-40 mesh) strainer and clean the suction line prior to starting the pump. 8. ensure that all piping is supported independently from the pump. 2. Perform inert gas purging of component internals. Store your pump only in an indoor. If no flow measuring device is installed there is no way to determine accurately where on its curve the pump is operating. Sundyne recommends installation of a discharge check valve to prevent reverse rotation. Sundyne recommends using a straight pipe assembly of at least three times the length of the pipe diameter. welding slag. Use desiccant bags. Note: Sundyne Recommends installation of a differential pressure instrument across strainer to indicate strainer condition. These conditions will maintain constant temperature and humidity. Ensure oil flooding of gearbox internals. 7. All piping must always line up with the pump flanges. or other foreign particles during initial startup. Suction and Discharge Piping Please adhere to the following best practices for installing and maintaining suction and discharge piping: 1.Instruction and Operation Manual 1. 2.

The liquid must be clean to 5 microns. Mounting Vertical Units Without Stands For all vertical units without stands.5 to 3 gpm (2 to 12 liters/min) with an inlet temperature of 60o to 120oF (16o to 49oC). The pump should be mounted on a rigid foundation. secured in position by one-inch diameter bolts. which will flow through the seal cavity. and inlet pressure as indicated on the pump specification sheet. The bolts should be installed in the foundation as shown on the installation drawing. Figure 1. Introduce the buffer liquid into port 7. Note: For most applications. Seal Housing Port Identification Liquid Buffer System For double liquid seals and tandem liquid seals. a liquid buffer system is used. Always maintain the pump seal environment as detailed on the specification sheet that accompanies each unit. 9 . Buffer flow should be 0. The length of the bolts should be sufficient to extend at least ½inch above the nut. Note: Port 1 must always be open so that it is free to drain. Ensure that the specified seal environmental control system is properly installed and that the ports are open (or plugged) as indicated in Figure 1. a mounting base is recommended.Instruction and Operation Manual Seal Environmental Control System A seal environmental control system may be required depending upon the pump seal arrangement and application. a standard control system can be obtained from the factory. and out from port 2.

this shaft must be lubricated at each end with one tube (5cc) of anti-fretting compound (Sundyne Part Number MP01AA10). After grout has been applied. The nuts on the foundation bolts should not be tightened until the grout has set for at least 48 hours. Also available are solid shaft drivers coupled to the gearbox with a flexible coupling. The base plate should be leveled prior to grouting.Instruction and Operation Manual Mounting Vertical Units with Stands (LMV) Grouting of the base plate is required for all vertical stand units. Base Mounted (BMP) Units Grouting of the base plate is required on all BMP units. Driver and Coupling Drivers are normally shipped separately from the gearbox and pump. The top of the stand (driver mounting surface) should be leveled by shimming under the base prior to grouting the channels that are to be filled with grout through the access holes. When a splined interconnecting shaft is supplied. it must be allowed to set for at least 48 hours before tightening foundation bolts. Drivers are to be installed and maintained in accordance with the manufacturer’s instructions. 10 .

keyways. The driver coupling hub is mounted on all motors and turbines shipped directly from Sundyne. 6.” Figure 4. Ensure that the coupling hub bore.or more if necessary. The gearbox coupling hub is normally mounted at the factory. When installing flexible couplings. Determine the end gap (the distance between each coupling hub) for the size of coupling provided. 2. verify that the coupling bolts and washers can be assembled (Figure 4) from the motor side of the hub when installed. Dimension Y 4. and shaft are clean and free from burrs. Dimension X Figure 3. Scribe the shaft to show dimension Y. to the datum face of the driver adapter. use the following procedure when installing Falk or Thomas couplings: 1. If these pieces do not assemble. Driver Coupling is Not Mounted If your product is received without the driver coupling hub mounted. Subtract the end gap value from dimension X to determine the distance from the driver datum face to the coupling hub face. Figure 2. Measure the distance from the top surface of the gearbox hub. 5. use those supplied by Sundyne to ensure tolerance of parallel and angular misalignment. This value is referred to as dimension “Y. Position the hub at the scribed line on the shaft. Heat the hub in an oil bath or oven to approximately 250oF (121oC). Coupling installation for turbine drivers is identical to that for motors. Refer to the Coupling Specifications tables in the Specifications section of this manual for specific measurements. 7. Tighten the hub key set screw. Use flexible disc couplings or gear type couplings if not using those supplied by Sundyne. insert short bolts with bevel washers into the hub flange before fitting them onto the shaft. 8. Note: Before the hub is installed onto the flexible disk couplings. Assembly of Coupling Bolts and Washers 11 .Instruction and Operation Manual Flexible Coupling for LMV Units Without a Vertical Stand Note: Lock out the driver starting switch before working on the coupling. so that the hub will slide onto the motor shaft. This measurement is referred to as dimension”X”. and axial end float. Also determine that the key fits in the keyways. 3.

• Cool water must be provided to the tube side at a maximum pressure of 150 psig (11 kg/cm2)(103. They are: • • • • Gearbox sump Main lube pump Oil heat exchanger Oil filter The lube pump intakes oil from the sump and passes it internally to an externally mounted manifold. the filter. and back into the gearbox. the following conditions must be met. MA01AA01 (right). Oil Manifolds There are two standard oil manifold configurations. 12 . The oil is then passed through the heat exchanger. Heat Exchanger Manifolds MA01AA78 (left). the standard manifold is MA01AA01.Instruction and Operation Manual LUBE SYSTEM Lube System The internal lube oil system engineered for Sundyne pumps consist of four major components. • The optional air-cooled heat exchanger should be controlled to maintain the same gearbox sump temperatures as above. MA01AA79 (center). For units purchased prior to 1991. Air pockets can cause oil starvation at the bearings. Gearbox Heat Exchanger The standard heat exchanger is a shell and tube water-cooled type. Note: The heat exchanger installation is a Sundyne assembly and should not be rearranged. Figure 5. MA01AA78 for units without heat exchangers and MA01AA79 for units with heat exchangers. Coolant flow must be controlled to maintain a gearbox sump temperature between 140°F and 160°F (60°to 71°C). Mount the heat exchanger lower than the oil filter to prevent air pockets in the lube oil lines at start up. it then drains back into the sump. Maximum recommended temperature is 180°F (82°C). For optimum performance. The heat exchanger is NEVER mounted higher than the filter. Once the oil is passed through the bearings.5Kpag).

must not exceed 20’ (6m). Refer to the Lube Oil Specifications in the Specification section of this manual for more information.Instruction and Operation Manual Figure 6. The MA01AA01 model requires a ¼” sockethead pipe plug in the filter manifold when using the gearbox heat exchanger. Two types of sump heaters are recommended for these conditions–electric or steam. A sump heater is required when these conditions may exist.D. Note: Interconnecting piping is the purchaser’s responsibility unless the piping is included with packaged units. including fittings. The plug must be All connecting piping. Gearbox Sump Heater (optional) When gearbox oil temperature falls below –20°F (-29°C) it becomes too viscous for proper lube pump operation. Remote Heat Exchanger All air-cooled heat exchangers as well as some large water-cooled heat exchangers must be mounted away from the gearbox. The minimum requirement of all piping is 5/8” (16mm) inner diameter (I. then the pipe diameter must be increased accordingly.) tubing or piping. Note: Sundyne recommends that the oil level must be within ¼” of top of the round sight glass when the machine is static (refer to the mark labeled “MAX”).When the pump is in operation.S. the level will be approximately ¼” below the MAX level. Note: Oil filters other than Sundgard -OEM filters will void the Sundyne warranty. Heat Exchanger Mounting for MA01AA01 (units prior to 1991) removed when the heat exchanger is not being used. 13 . ® The gearbox oil and filter should be changed every six months. Overfilling will cause overheating/ excessive foaming. Do not overfill the gearbox. not including the oil contained within the auxiliary piping and heat exchanger.6 liters) of oil. If pipe lengths exceed 20’ (6m). The oil level must always be maintained as recommended by Sundyne. SundGard® Oil Filter The specially designed oil filter is rated for 3 microns at a beta ratio of 200. quarts (6. with bubbles filling the rest of the glass. Gearbox Sump The gearbox sump holds approximately seven U.

7 kg/cm2) 14 . The main lube pump is a positive displacement gear type pump directly driven by the input shaft. The kit consists of: • • • • Motor driven positive displacement pump Check valve Gages Necessary piping Figure 7. Lube Oil Schematic To start the pump. Note: Only allow shut down of pre-lube pump after main driver is at full operating speed.2kg/cm2). Oil Pressure During normal operation the gearbox internal lube pump will maintain oil pressure between 15 and 60 psig (1. allow several minutes of operation to bleed trapped air from the system. This oil pressure can vary depending on the bearing configuration and characteristics of the oil being used. Note: Never operate the gearbox with oil pressure less than 10 psig (0. There should be a minimum indication of 7 psig (0. A pre-lube system is required on some pumps. allow the pre-lube pump to run for approximately 30 seconds.5kg/cm2) maintained for 30 seconds before starting the main driver. If the oil piping has been drained.0 and 4.Instruction and Operation Manual Main Lube Pump and Lube Oil Priming Kit Note: Use the auxiliary lube oil priming pump to circulate oil around the heater when the main drive motor is not running.

Verify that gearbox lube oil pressure will be achieved by priming the lube oil system and expelling all of the air that is potentially trapped. Prime the lube oil system The following actions must occur at the time of initial pump installation and following every re-installation after maintenance that required the draining/removal of the gearbox lubricating fluid. 1. Port 1 must be open. Remove the gearbox fill-vent plug and the filter-breather cap from the fill opening on the gearbox.) the factory should be consulted to ensure that the run-in conditions are compatible with the pump. Where applicable. the pump can now be routinely started without the need of jogging. 6. Fill the gearbox with oil. Always check to ensure that the discharge valve is partially open. Priming can be achieved by either operating the (optional) auxiliary lube oil priming pump or by jogging the main driver connected to the gearbox (oil pressure should be observed by the second or third jog . Add oil as necessary through fill fitting until oil level stabilizes in sight glass. If double seals are used. conservative activity that can be quite useful to ensure long service life of the Sundyne high-speed products by providing a fluid film of lubricant on the surfaces of bearings and gears. calibrate flow instruments and other transmitters.4 mm) from top of oil level sight glass with lube oil which conforms to the specification in Table 8. Note: Jogging is required for initial installation or following reinstallation after maintenance and re-filling of gearbox lubricant. remove the plug on top of the oil filter (item 924g) manifold and fill the oil filter and the heat exchanger with oil (Figure 6). Note: Never start the pump against a closed discharge valve.Check utility connections. Auxiliaries . Maximum allowable back pressure on Port 1 is 5 psig (0. start-up of idle reserve units. After priming the lube oil system. verify switch and instrument connections and set points. If an auxiliary lube pump is not used. verify that auxiliary piping is per Sundyne drawings. 2. Jogging is also used to verify proper direction of rotation for the main driver. 5.each of 2-3 seconds duration).6 liters). Jogging is a prudent.35 kg/cm2). Check to ensure that the driver has been serviced per instructions provided by the driver manufacturer. 7. Check the pump specification sheet and outline drawings for seal environment requirements. After priming the lube oil system as defined above. operate auxiliary lube pump to fill heat exchanger and filter. Run-in of pump: If the pump is to be run under conditions which are considerably different from those conditions listed on the spec sheet (such as a change in specific gravity. 3.Instruction and Operation Manual START UP Start-Up Procedures Perform the following tasks to start the Sundyne pump. Replace the filter breather cap on the fill-opening fitting and replace the fill-vent plug. Fill gearbox within ¼ inch (6. Be sure seal housing port piping is properly connected. check the oil level in the gearbox sump. 4. Flushing screens should be installed in all field assembled piping connections. start-up 15 . suction pressure. etc. flow rate. The gearbox alone requires approximately 7 quarts (6. This would include switching of main/stand-by units. and add oil as necessary. Units remaining idle should be jogged once a month to prevent the bearings from brinelling and to prevent internal rusting. buffer fluid must be pressurized before suction pressure is applied to the pump.

follow the start up procedures for your desired configuration. Adjust the relief valve on the auxiliary pump to provide 25 psi (1. 3. If an auxiliary lube system is installed. It should run for a minimum of 5 seconds at minimum pressure before the main driver is started. An increase in oil pressure should be observed. Note: Sundyne recommends installing separate bypass loops around each pump for additional operational flexibility. Adjust the heat exchanger cooling flow to regulate the gearbox sump temperature between 140° and 160°F (60o and 71°C). Note: Do not operate the pumps at their peak head capability. Non-operating units should be started/used every 9-12 months on an alternating basis. If the process fluid is near its vapor pressure. Pressure switches and time delays can be used if automatic start sequences are desired. c) After the start of the main driver. Sundyne recommends that separate flow controls be used on each pump to provide a lower minimum flow range than is achieved by pressure control. Approximately one hour may be required to stabilize the temperature. 2. 8. Maximum recommended temperature is 180°F (82°C). Single Operation Start the pump with the suction valve open while throttling the discharge valve. 1. This will ensure that the pump will reach the design flow operating point. etc. a) At the initial startup or after changing the lube oil. Start the second unit with the bypass valve set to maintain the flow above minimum flow. b) The auxiliary system is intended to provide oil before starting the main driver. Controlling the Pump During Startup To ensure control of the pump during start up. oil pressure will be supplied by the main lube pump inside the gearbox. Open the discharge valve on the second unit so that the design flow of both units is maintained. open the supply vessel seal cavity vent so that the pump can fill with liquid. Parallel Operation To prevent back-flow. Start the first unit as described in the Single Operation instructions. Shut down the auxiliary pump within two minutes of the main driver start.76 kg/cm2) oil pressure to the system. run the pump for several minutes to work any trapped air out of the piping. place check valves in the discharge piping of each pump. it should be used in the following manner.Instruction and Operation Manual of emergency units. 9. 16 .

the system curve must intersect the pump characteristic curve at a significant angle. Figure 8. vibration. Entrained gases can cause damage to mechanical seals with the exception of double seals. • Liquid reaching the impeller eye must have enough vapor pressure to prevent the fluid from flashing to a gas in the impeller. centrifugal pumps can tolerate up to 2% of gas (by volume). Resonance in the discharge line can accentuate noise. Two conditions must exist to prevent turbulence at the eye of the impeller. • Proper suction piping. System Head Curve The point of intersection between the system curve and the pump characteristic curve determines the flow or operation for the centrifugal pump. and damage to the pump. primarily when a control valve is located an excessive distance downstream from the pump. For steady flow to occur. operation must be suspended until the cause is determined and corrected. In high speed. The following diagram gives examples of satisfactory and unsatisfactory angles of intersection. see suction piping section. Entrained Gases The head and capacity of centrifugal pumps will be reduced by gas that is drawn in with the liquid. this sound may not be discernable. it will cause cavitation. Continued use may cause damage to the pump. Suction Conditions Improper flow of liquid into the impeller is the most common operational abuse of centrifugal pumps. contact Sundyne for further instruction. If you have entrained gas. single stage pumps. 17 . If this condition occurs. When centrifugal pumps cavitate the noise sounds like the pump is “pumping gravel”. Under normal operating conditions.Instruction and Operation Manual OPERATION & CONTROL Operation of Sundyne Pumps Under normal operation. Experienced pump operators will be aware of jeopardizing factors and their effects. Typical Operation Minimum Flow Conditions Vibration and noise will occur during operation of centrifugal pumps if either of two conditions exist: • • Internal flow separations Recirculation at low flow conditions If the operator is noticing excessive noise or vibration. several factors must be taken into consideration to ensure successful pump operation. which can damage the impeller and inducer. Cavitation can be prevented by maintaining suction pressure at a high enough level and suction temperatures low enough to maintain Net Positive Suction Head (NPSHa) available greater than Net Positive Suction Head (NPSHr) required by the pumps.

the flow through pump A indicated as A1 on the preceding curve. Parallel Units Common Valve Parallel Operation Maximizing control is critical when operating centrifugal pumps in parallel. When the control valve is partially closed to create system curve E. During internal boiling. At the same time. The pressure in the manifold is set at P1. This is demonstrated on the following diagrams. However. the curve E and lower pump curve B are practically parallel. Since pump B would effectively be deadheaded. Parallel Operation FLOW Figure 10. then flows through pump A and B are A2 and B2 respectively. it is assumed that pump A produces a slight amount more head than pump B. The system curve D could represent a system with the control valve wide open while curve E could represent the same system but with the throttle valve closed to reduce flow from flow 1 to flow 2. The pumps are arranged with a common manifold as shown in Parallel Units Common Valve figure. then pump B would cease to flow entirely. unrestricted manifold connects two pumps at the discharge head. the flow through pump B is indicated as B1. If the throttle valve were closed even further. it could encounter liquid slugging and probable damage to the pump. If a simple. All pumps will see the same discharge head at a given time. pump flow is likely to fluctuate erratically and not respond to control valve position. The lack of a significant angle of intersection means that the system is unstable. will provide only flow 2. Proper selection of a control system can prevent this situation.Instruction and Operation Manual Note: The curve for pump A has a significant angle of intersection with system curves D and E. Figure 9. Pump curve B. if the throttle valve is closed to cause the manifold pressure P to rise to P2. the fluid in it would heat up and boil. The characteristic curves of two pumps designated A and B are demonstrated in the Parallel Operation figure. One pump can overpower the other in regards to head at a lower total flow. the discharge head of one pump is imposed on the other. Since no two pumps will have exactly the same performance. on the other hand. 18 . even with the control valve wide open (curve D).

Lifting gearbox from pump casing. Lift the gearbox and seal housing up off of the pump casing. Remove the nuts from the pump casing studs. 19 . STEP 3 Install the anti-rotation device to prevent impeller from spinning. STEP 2 Remove vent cap from gearbox. Note: Ensure the impeller is protected from coming in contact with any objects that may cause damage.Instruction and Operation Manual MAINTENANCE Disassembly of LMV-311 STEP 1 Remove attached hardware and lift the driver up off the gearbox. Installing anti-rotation device Note: Place the gearbox on a suitable support with the impeller pointing upward.

Note: The impeller is dynamically balanced and must be replaced or rebalanced if any signs of damage are visible. STEP 6 Remove diffuser cover using prying tools.Instruction and Operation Manual STEP 4 Remove inducer or impeller nut. STEP 7 Remove mechanical seal mating ring. Note: Groove on side of diffuser cover is for prying. Mating ring should slide right off. 20 . STEP 5 Remove impeller using prying tools. and not for an o-ring. Note: Left hand thread.

Instruction and Operation Manual STEP 8 Remove lower mechanical seal. Use extraction tool to slide o-rings up the shaft. STEP 9 Remove lower shaft sleeve and o-rings above and below shaft sleeve. Notice shaft sleeve next to impeller side o-ring. Remove three hex head screws and washers. 21 .

over shaft. Lifting the seal housing using a hoist. STEP 12 Remove seal housing. Use extraction tools to slide up. 22 .Instruction and Operation Manual STEP 10 Remove tandem-mating ring. STEP 11 Remove four bolts holding seal housing. Note: Use “S” hooks or eyebolts and hoist when possible to avoid personal injury.

Note: The gearbox mechanical seal can be replaced or rebuilt. Use extraction tool to remove o-ring.Instruction and Operation Manual STEP 13 Turn seal housing over and remove upper seal from seal housing. Remove three hex head screws and washers. Removing three hex head screws. STEP 14 Remove the o-ring from the upper shaft sleeve. 23 . Upper mechanical seal. STEP 15 Remove upper shaft sleeve. STEP 16 Remove gearbox seal screws and gearbox seal.

STEP 19 Invert the gearbox and remove fill and vent fitting. Slide the fill and vent pipe out of gearbox. Use a pipe wrench to remove the ¾ inch pipe elbow first. STEP 18 Remove gearbox seal mating ring. 24 .Instruction and Operation Manual STEP 17 Remove gearbox seal O-ring. use the pipe wrench to loosen the pipe and remove from the gearbox. Use extraction tool to remove O-ring. Next. Remove mating ring with extraction tools.

(7 total). STEP 23 Remove upper gearbox housing. STEP 21 Loosen close tolerance alignment pin. STEP 22 Drive close tolerance alignment pins out. Note: Use hooks or eyebolts and a hoist when possible to avoid personal injury. 25 . (2 pins). Use hammer to tap pin out. A mallet can be used to tap around the edges of the housing to loosen the idler shaft and assist the housing in lifting off.Instruction and Operation Manual STEP 20 Loosen and remove gearbox bolts.

Instruction and Operation Manual STEP 24 Remove idler shaft assembly. STEP 27 Technician is pointing to idler shaft. STEP 26 Remove the lube pump spring and the lube pump. 26 . Removing the idler shaft assembly disengages the upper idler and input shaft gears. STEP 25 Remove input shaft assembly. Extraction tool is touching anti-rotation pin. Inspect the condition of the lube pump antirotation pin.

Instruction and Operation Manual STEP 28 Remove bearing plate. STEP 30 Remove idler shaft assembly. STEP 29 Remove and inspect upper thrust washer. STEP 31 Remove high-speed shaft assembly. Washer will slide off of the shaft. 27 .

Remove the sump tube. 28 . STEP 35 Unscrew three hex head screws.Instruction and Operation Manual STEP 32 Remove and inspect lower thrust washer. Use fingers to remove journal bearing. Inspect the upper journal bearing for damage or signs of excessive wear. STEP 34 STEP 33 Remove and inspect upper journal bearing after removing from bearing plate. Remove input shaft lip seal.

Blowing out lube passages. STEP 38 Remove all the lube jets in lower and upper housing. Repeat step 33 for removal of lower journal bearing. Use hex key to remove the lube jets. Using air tool to blow out lube passages. STEP 40 Remove diffuser from the pump case. STEP 39 Blow out lube passage. Install three 5/16 eyebolts into the diffuser to use for hoisting the diffuser off of the pump case. 29 .Instruction and Operation Manual STEP 36 Remove lower journal bearing. STEP 37 Remove lower bearing shims.

Note: Use hoist when available to prevent personal injury.Instruction and Operation Manual STEP 41 Lift the diffuser from the pump case. 30 .

install a new bearing assembly. If metal is smeared into radial lube grooves of the washer face.010 inch (0. During reassembly. If the tilting pads do not fit freely. Non-approved bearings may jeopardize the mechanical integrity of the gearbox and pump. if used seal housing. on it’s bearing journals. Remove any high spots on the end surfaces of the lower shaft sleeve and impeller hub to insure that the seal rotating face will not be distorted by clamping force of the impeller bolt. wedge rings.0018 inch TIR max). Check the gearbox input shaft for freedom of rotation after the pump is assembled and all bolts are tightened per Table 11.4960 inches If the shaft has bearing or washer materials on it’s surface Shows signs of overheating Shows wear to a depth greater than 0. excessive seal face wear and any binding of the seal face washer. and impeller using an o-ring repair kit. and have runout measured at the impeller fit (0. High-Speed Shaft Inspect the High Speed Shaft at the thrust washer and journal bearing contact areas.Instruction and Operation Manual Inspection.03mm) Inspect upper and lower thrust washers or tilting pad bearing assembly. Replace or lap the seal rotating face if the wear track is rough or worn to a depth greater than 2 helium light bands. To check straightness. The impeller may rub on the diffuser cover plate (15) until o-rings (936D and 936E) are compressed by tightening hex nuts (914A). or if they show signs of metal pick-up or overheating.28mm) due to the clearance in the bearings.001” (0. Gearbox Mechanical Seal Replace bearings if: • • • They have been in operation for over three years If rotation is not smooth If outside of inside diameters are worn Carefully inspect the seals for abrasive particles. Replace or rebuild a faulty mechanical seal. and springs. Note: Only replace bearings with manufacturer’s approved replacement bearings. A combined total of 0. Note: The radial “free play” of the high speed shaft can be as high as 0. Excess material removal will result in incorrect seal face loading causing increased seal leakage. Note: Refer to the Specifications section of the manual for all bearing and shaft clearances. throttle bushing. All o-rings that were disturbed by disassembly should be replaced.25mm) maximum may be removed from the surfaces of the pump and gearbox seal rotating faces. carefully check the torque values listed in Table 11. the shaft must be placed in V-blocks. Reassemble the seal. It is not possible to check for shaft straightness while the gearbox is assembled. Cleaning and Repair Inspecting All Bearings new washer. install a 31 . Seals may be rebuilt by replacing the seal face washer. Replace the shaft and gear assembly if: • • • • Outside diameter of shaft is less than 1. A seal repair kit is available. o-ring.011 inch (0.

Bearing and Shaft Clearances 32 .Instruction and Operation Manual Shaft Sleeve Ensure that there are no high spots on the end surfaces of the shaft sleeve or the impeller hub.0076mm). High spots will distort the seal rotating face due to the clamping force of the impeller bolt. Ensure that shaft sleeve end faces are parallel within 0. Bearing and Shaft Clearances Figure 11.0003” (0.

Note: Torque to 40 in-lbs Note: Above picture has thrust washer already installed over journal bearing. Insert 3 hex head screws. 33 . STEP 3 Install lower thrust washer if not already in place. Note: Using a torque wrench to tighten screws.Instruction and Operation Manual Reassembly of the LMV-311 STEP 1 Insert shim under lower journal bearing. STEP 2 continued STEP 2 Install lower journal bearing.

Instruction and Operation Manual STEP 4 Install high-speed shaft assembly. STEP 6 Re-install the upper journal bearing into the bearing plate. STEP 8 Install bearing plate without gasket using alignment pins. Thrust washer is silver disc in center. Using alignment pin to install the bearing plate temporarily. 34 . Note: Tighten hex head screws to 40 in-lbs. STEP 7 Install new thrust washer. STEP 5 Re-install the sump tube into the bearing plate.

STEP 12 Lubricate the journal bearings. 0. STEP 10 Inspect endplay of the high-speed shaft.002” Lubricating the high-speed shaft. Measuring endplay of High Speed Shaft. STEP 11 Remove bearing plate and install lower housing gasket and o-ring at oil passage.0. Note: For complete instructions for checking endplay refer to the “Procedure for Checking High Speed Shaft Endplay” later in this manual. journal/thrust face with standard gearbox lubricant. Clamping the bearing plate to housing. Note: “C” clamps can be utilized to perform this task. Note: Endplay must fall within these tolerances. 35 .015” +/.Instruction and Operation Manual STEP 9 Clamp bearing plate to the lower gearbox housing. high-speed shaft.

STEP 15 Install the bearing plate.Instruction and Operation Manual STEP 13 Lubricate the lower idler bearing. STEP 16 Install lube pump. 36 . Note: The idler shaft assembly sits at a slight tilt to allow installation of the bearing plate. STEP 14 Install idler shaft assembly.

Instruction and Operation Manual

STEP 17
Install lube pump spring.

STEP 19
Install input shaft assembly.

The lube spring sits inside the lube pump.

STEP 18
Lubricate the lube pump.

Note: Notice the input slots for the oil pump drive pins.

STEP 20
Push on input shaft to verify engagement of drive pins.

37

Instruction and Operation Manual

STEP 21
Set idler shaft assembly in place and engage input gears.

STEP 22
Lube input shaft bearings and upper idler bearings. Note: Use hoist when available to prevent personal injury.

STEP 25
Install close tolerance alignment pins.

STEP 23
Install upper housing gasket and o-ring.

STEP 24
Install upper gearbox housing. Note: Lower carefully in order to slide bearings into bearing liners. Note: Install first pin as noted on the bearing plate.

38

Instruction and Operation Manual

STEP 25 continued

STEP 26 continued

STEP 26
Install new lip seal. Note: Use lip seal installation tool #TH006AA-47 to install lip seal.

Installing the lip seal. Putting lip seal onto lip seal installation tool.

39

STEP 28 Install fill and vent fitting. Note: Torque to 65 ft-lbs. 40 . Installing washers and nuts onto gearbox bolts. STEP 29 Install shaft anti-rotation device to prevent the impeller from spinning. Use pipe wrench to tighten fitting after sliding into place.Instruction and Operation Manual STEP 27 Install remainder of gearbox hex head bolts. Note: Use pipe dope on all pipe threads.

Instruction and Operation Manual STEP 30 Turn gearbox over. 41 . STEP 33 Install gearbox seal o-ring onto gearbox seal. STEP 34 Install gearbox seal. STEP 32 Install gearbox-mating ring o-ring. STEP 31 Install gearbox-mating ring.

Instruction and Operation Manual STEP 35 Install three gearbox seal hex head screws. STEP 36 Install thermal barrier gasket. STEP 40 Install seal housing cap screws. 42 . Note: Use “S” hooks or eyebolts and hoist when available to prevent personal injury. STEP 38 Install upper shaft o-ring. STEP 39 Install seal housing. Note: Torque screws to 75-80 in-lbs. STEP 37 Install upper shaft sleeve. Note: Torque screws to 35-40 ft-lbs.

STEP 41 Install upper seal mating ring Install o-ring on mechanical seal. Note: Torque three hex head screws to 95 to 102 in-lbs.Instruction and Operation Manual STEP 40 continued STEP 42 Replace the mechanical seal. STEP 43 Install lower shaft sleeve o-rings. 43 .

STEP 49 Install impeller o-ring. Note: Rotate cover to engage alignment pin with hole in seal housing. Note: Torque to 95-102 in-lbs. STEP 47 Install diffuser cover o-rings. 44 . STEP 48 Install the diffuser cover onto the gearbox. STEP 45 Insert lower seal screws.Instruction and Operation Manual STEP 44 Install lower seal o-ring and seal. STEP 46 Install lower mating ring.

Note: Torque inducer to 36-40 ft-lbs.Instruction and Operation Manual STEP 50 Install impeller (spline driven). STEP 52 Replace upper diffuser o-ring. STEP 53 Install lower diffuser o-ring. Left hand thread. Note: Fully engage inducer stud into the inducer before installing into the assembly. 45 . Note: Lower diffuser o-ring may require stretching before installation. STEP 51 continued STEP 51 Install inducer.

STEP 54 Lower the diffuser back onto the pump case. Note: The impeller may rub on the diffuser cover plate until all the o-rings are compressed by the tightening of the hex nuts.Instruction and Operation Manual Step 53 continued STEP 55 Install seal housing and gearbox onto the pump case. bearings should be pressed onto the shaft using a press which only contacts the inner race. No more than 0. STEP 56 Install pump case nuts onto posts. gears.001 inch (0. Lower diffuser o-ring inside the diffuser. 46 . and shaft shoulders. Bearing damage will occur by pressing or pulling the outer race. Note: Torque to 250-275 ft-lbs. spacers.03mm) gap should exist between the bearings. Note: When installing new anti-friction bearings.

calculate the shim thickness required to place the shaft within the proper STEP 13 Position the bearing plate (102) on the lower half of the gearbox. With no shim spacers installed. STEP 10 Install the lower thrust washer (155A-if used) with the flat side on the bearing surface and replace the high-speed shaft. If outside of tolerances. STEP 8 Install the required shim spacers in place on the gearbox output housing and replace the lower journal bearing. and the lower journal bearing. Do not install the o-ring and gasket.05 mm). thrust washers (if used). STEP 4 Install the bearing plate (102) using two largediameter alignment bolts (909C).015 ± 0. tighten screws (905N). Place the high-speed shaft assembly into the gearbox output housing. If endplay is not within this limit. tighten screws (905M). Sundyne recommends checking endplay during any re-assembly. Do not allow the idler shafts lower ball bearing to slide into the bearing retainer at this stage of the assembly. move the shaft up and down while measuring the total endplay with a dial indicator or depth micrometer. STEP 1 Install the lower journal bearing (151A) into the gearbox output housing (101A). 47 . STEP 11 Install the upper thrust washer (155B-if used) with the flat side on the journal bearing’s surface. Note: Never install shims behind the upper journal bearing. recalculate shims required and repeat steps 3-9. Ensure that the lube passage orings (936T) and housing gaskets (105) are positioned correctly. To obtain correct shaft endplay shim spacers must be installed as required. STEP 12 Continue the reassembly of the gearbox by placing the idler shaft (140) in the lower half of the gearbox. With no shim spacers installed. STEP 2 Install the upper journal bearing or bearing assembly (151B) into the bearing plate (102).002-inch (0. STEP 6 Remove the alignment bolts (909C) and bearing plate (102) with upper journal bearing (151B).Instruction and Operation Manual Procedure for Checking the High-Speed Shaft Endplay The endplay of the shaft MUST be measured if any of the following parts have been replaced: • • • • • High speed shaft assembly Thrust washer Output housing Journal bearing Bearing plate clearance range. proceed to step 10. STEP 5 With the shaft in a vertical position. Clamp the bearing plate to the output housing with two “C” clamps or bolts.38 ± 0. place both upper and lower thrust washers (155B and 155A) into the upper and lower journal bearings. Note: All parts must be dry and free of oil. STEP 7 Remove the high-speed shaft. Select the required thickness shim using 158 series shim spacer sizes. Shaft endplay must be 0. STEP 9 Repeat steps 3-5 to verify correct endplay. Install attaching bolts (905M) and tighten. STEP 3 If used. If within specifications. A light grease may be used to hold the thrust washer in place.

engaging the four gears. 48 . The top surface of the bearing should be even with the top of the bearing liner.Instruction and Operation Manual STEP 14 Install the low speed shaft assembly into the bearing plate bearing liner with the shaft aligned so that the lube pump drive pins slip into the low speed shaft. The idler shaft can then be allowed to drop into the lower bearing liner.

Check suction line for air leak if suction pressure is lower than atmospheric. Note: Impeller and driver rotate in the same direction. 49 . NPSH reduced by presence of more volatile fluid in process fluid. Note: Impeller and driver rotate in the same direction. Insufficient total head. Excessive pressure drop through suction piping. no pressure at start-up. Flow too high. Diffuser discharge throat partially plugged or impeller damaged by passage of a solid particle. Allow more cool-down time if pumping low temperature fluid. Flow too low. Direction of driver shaft rotation must be as shown by arrow on pump casing. Flow restricted by vapor pockets in high points of suction line. Failure of drive component. Disassemble and inspect. Bypass part of pump discharge to supply tank. Clean these areas of all obstructions and restore surfaces to a smooth polished finish free of all corrosion pitting. or item missing from assembly. Situation/Symptom No flow. NPSH actually lower than NPSH requirement listed on specification sheet. Refer to solutions listed under “No flow. NPSH actually lower than NPSH requirement listed on specification sheet. no pressure at start-up”. Reverse direction of rotation. Gearbox and Pump Diagnostics Possible Cause Investigative/Corrective Action Bleed all vapor or air from port 6. (It is possible for the pump to develop greater than 50 percent design total head in this condition). such as interconnecting shaft or impeller key. Table 1. Entrained air or vapor in pumped fluid. These factors are: • • • • Temperature Specific gravity Suction pressure Driver speed • • Flow rate Control characteristics These factors as well as internal problems must be considered when analyzing pump system performance. Edge of diffuser throat must be sharp. Wrong direction of driver shaft rotation. Check total head and flow rate against performance curve. Suction tank level or pressure too low. Suction line blocked – check suction screen and valve.Instruction and Operation Manual TROUBLESHOOTING Gearbox & Pump Diagnostics Several system factors may affect the performance of the pump. The following table gives diagnostic information that can be useful when analyzing gearbox and pump performance problems. causing overheating of fluid resulting in internal boiling and unstable pump operation. Pump not completely filled with liquid. Direction of driver shaft rotation must be as shown by arrow on pump casing. Increase through-flow rate.

Corrosion/erosion of diffuser and cover surfaces will result in a significant horsepower increase.Instruction and Operation Manual Situation/Symptom Possible Cause Corrosion and/or erosion of diffuser throat (may also be accompanied by corrosion/ erosion of diffuser and cover surface adjacent to impeller). Insufficient total head cont. Remove gearbox oil level sight glass and inspect bottom of sump for wear particles. Pressure gauges or flow meters in error Driver overloaded. Opening of the inlet area of the throat will result in higher flow rate and horsepower consumption. Fluid specific gravity or viscosity higher than values listed on specification sheet. Change of gearbox oil from normal color to milky pink or yellow Gearbox oil contaminated with water or process fluid. Electrical failure in electric driver. Viscosity higher than five centipoise will cause reduced head and flow and increased power consumption. Corrosion pitting on surface of diffuser cover or diffuser. Bearings are probably not damaged if no wear particles are present. Investigative/Corrective Action If edge of throat is no longer sharp and smooth or has opened in size. Inspect that seal housing port 1 and other seal drains are open for unrestricted seal leakage flow. Refer to solution for insufficient NPSH under “No flow. head-rise may be reduced. Check actual viscosity and specific gravity at operating temperature. Process fluid specific gravity or viscosity different from values shown on specification sheet.” above. adjacent to impeller blades. erosion or corrosion resulting in roughness or increased area will increase horsepower consumption. Check voltage and voltage balance between phases. no pressure at startup. Calibrate instrumentation. Driver speed too low. Note: A larger throat size than design will allow a higher flow and horsepower for a given head rise. Check flow through external plumbing. Excessive recirculation from discharge to inlet. Check circuit breaker heater size and setting. Head rise is also reduced by this condition. Flow rate too low. Insufficient NPSH available. Increase flow rate through pump. Check diffuser throat area at the inlet. Remove driver and check for freedom of rotation. Disassemble pump and inspect. gearbox or pump. correct spacing of pump and gearbox shaft assemblies. Remove fluid end and search for any mechanical failure. Clean these areas of all obstruction and restore surfaces to a smooth polished finish. Rough or pitted surfaces can cause friction losses which will significantly increase horsepower consumption. Check actual viscosity and specific gravity against value listed on specification sheet. Inspect shaft sleeve o-rings. Pump o-ring (936C) damaged or missing. Mechanical failure in driver. Current for each phase should be balanced within three percent. Check control valve. Add bypass to suction tank if necessary. Inspect gearbox heat exchanger for leakage. Check for excessive pump seal leakage. Defective flow control valve. Check speed against value listed on specification sheet. Excessive discharge pressure pulsations. 50 . Integral centrifugal separator orifice worn.

Bleed vapor from seal cavity and restart. Heat exchanger fouled or coolant shut off. Replace shaft seal if required. Investigative/Corrective Action Correct pump suction condition causing cavitation. 51 . Shut down the unit and check oil level. Install double seal if loss of suction cannot be prevented. Replace shaft seal if required. High gearbox temperature.) Supply external clean seal flush or double seal if particles cannot be removed by separator. Check upper gearbox housing drain port for leakage. Possible Cause Gearbox journal bearing failure. Repair procedures for mechanical seals are listed in this manual under Maintenance. Leakage through heat exchanger into cooling fluid. Use purge of dry nitrogen gas through ports 2 or 7. Seal icing on low temperature pumps or icing when handling fluids which vaporize at a temperature of less than +32°F (0°C) at atmospheric pressure Quench with compatible fluid which will not freeze at pump temperature through seal drain port 2 or 7 to prevent ice formation on atmospheric side of seal during start-up and in running condition. Incorrect lubricant. Low gearbox temperature. Check oil level and adjust. Pump Mechanical Seal Diagnostics The following table contains diagnostic information that is applicable to single seal. Table 2. Investigative/Corrective Action Install replacement exchange gearbox or repair gearbox as outlined under “Maintenance”. Sudden increase in seal leakage (continued) Solid particles in seal cavity or seal spring area (seal faces usually have rough scratched appearance).Instruction and Operation Manual Situation/Symptom Shaft sleeve rubs on inside diameter of seal. Low speed shaft seal (115) leakage. Possible Cause Severe cavitation or loss of suction causing vibration and bouncing of seal face. High speed shaft mechanical seal (60C) leakage. Check coolant flow and/or clean heat exchanger. Pressure test heat exchanger and replace if required. and tandem seal equipped units. Oil level too high. Clean orifices if necessary (plan 31 if so equipped. 60°C. double seal. Install double or tandem seal if ice is caused by water in process fluid or supply external seal flush of compatible fluid which does not contain water. Pump Mechanical Seal Diagnostics Situation/Symptom Sudden increase in seal leakage. Excessive oil foaming. High oil level. Excessive gearbox oil consumption. Adjust coolant to heat exchanger. Inspect for clogged integral centrifugal separator orifices. Check drain port for leakage. keeping oil temperature above 140°F.

Lightly lap surfaces of shaft sleeve and impeller hub which contact rotating seal face to remove high spots. Install double seal. May be caused by damage at assembly or thermal shock caused by seal running dry. Worn or damaged seal. Wear pattern on seal rotating faces not uniform. Prevent loss of pump suction. Prevent loss of pump suction or supply continuous external seal flush. Damage to mechanical seal secondary seal (Teflon® wedge or U-cup or elastomer o-ring). Use external seal flush or double seal arrangement.) Seal rotating face cracked or broken. Investigate fluid properties and determine suitable materials for replacement. Check for erosion and/or corrosion attack. Chemical attack of seal faces. Install double seal. Excessive radial high speed shaft movement. Check for correct impeller bolt/inducer torque. Edges of stationary face chipped and seal face worn. Install seal cavity bypass to suction tank. 52 . Install seal flush or double seal arrangement. Lap flat or replace seal. Supply cool seal flush. seal parts or o-rings. Check for cold flow of Teflon® o-rings. Check if damage exists on impeller and/or inducer which will indicate that a large particle went through the pump. Bent high speed shaft or severe out-of-balance. Loose stack-up of high-speed shaft attaching components. Deposits on the impeller/inducer causing unbalance. Wear pattern on stationary face smooth but not uniform. Check high speed shaft journal bearings and replace if necessary. replace with parts made from compatible materials.Instruction and Operation Manual Situation/Symptom Possible Cause Seal stationary face spring action is rough and sticky. If formation of solids causes sticky seal analyze fluid properties. Investigative/Corrective Action If parts are corroded. Disassemble seal and rebuild or replace per instructions in maintenance section. Install new seal faces. (Vapor flashing in seal cavity will cause excessive wear and/or cracking of rotating face.

156 in. Falk Steelflex Type Coupling Specifications Falk Coupling Size 40T10 Minimum 0.172 in.96 mm) Maximum 0.140 in (3.57 mm) 50T10 0.17 mm) 0.125 in.005 in.172 in.77 mm) 0. (4.17 mm) 0.56 mm) Normal 0.062in.17 mm) 0.30 kg-m) 200 in-lb (2.77 mm) 0. (4. (0.30 kg-m) 200 in-lb (2.125 in.36 mm) End Gap Operating Limits Total Indicator Reading Offset (Maximum) 0. (3.57 mm) 80T10 0.57 mm) 70T10 0. (3. (4.188 in.17 mm) 0. (6.77 mm) 0.56 mm) 20G 0.140 in.125 in.062 in. Falk Steelflex Type Coupling Specifications Falk Coupling Size Minimum 15G 0.062 in.127 mm) 0.188 in.125 in. (3.36 mm) 0.156 in. (3. (1.188 in. (0.250 in.Instruction and Operation Manual SPECIFICATIONS Falk Steelflex Type Coupling Specifications Table 3. (3. (1.062 in.005 in.57 mm) 60T10 0.127 mm) 0. (3.125 in.22 kg-m) 420 in-lb (4.30 kg-m) 200 in-lb (2. (1.30 kg-m) Falk Double Gear Type Coupling Specifications Table 4.005 in.57 mm) End Gap Normal 0.83 kg-m) Bolt Torque 53 .005 in. (0.188 in.127 mm) Angular (Maximum) 0. (4. (3. (1.17 mm) Maximum 0.062 in. (3.15 kg-m) 200 in-lb (2. (0.77 mm) 0.96 mm) 0. (4. (1. (4.35 mm) Cover Bolt Torque 100 in-lb (1.127 mm) 280 in-lb (3.

(22. (30.938 in. (23.97 mm) 301 1.81 mm) 0. (33.219 in.876 in. (25.73 mm) 1.127 mm) 0.24 mm) 201 0. (28.81mm) 1.35 mm) 1.251 in.313 in. (0.127 mm) 280 in-lb (3.22 kg-m) 420 in-lb (4.500 in.938 in. (30. (35.48 mm) Cover Bolt Torque 156 in-lb (1.46 kg-m) 516 in-lb (5. (23.15 kg-m) 54 . Thomas Type DBZ Coupling Specifications Thomas Coupling Size 163 Minimum 0. (38.005 in.126 in. (22.83 kg-m) Bolt Torque Thomas Type DBZ Coupling Specifications Table 6.407 in.005 in.188 in.406 in. (0. (0. (31. (25.59 mm) 263 1.24 mm) 226 1.Instruction and Operation Manual Falk Double Gear Type-Vertical Specifications Table 5.41 mm) 1.18 mm) 1.41 mm) 1.127 mm) 0.80 kg-m) 300 in-lb (3. (35.95 kg-m) 756 in-lb (8. (40.005 in.594 in. (0.127 mm) Angular (Maximum) 0.10 mm) Maximum 1.005 in. Falk Double Gear Type-Vertical Specifications Operating Limits Falk Coupling Size (Total Indicator Limit) Offset (Maximum) 15GL 15GV 20GL 20GV 0.76 mm) 1.72 mm) End Gap Normal 0.005 in.876 in.72 kg-m) 1140 in-lb (13.005 in.

(14.563 in.88mm) 0. (0.469 in.127mm) 0.91mm) 0.30mm) SN262 0.95 kg-m) 756 in-lb (8. Thomas SN Spacer Type Vertical & Horizontal Coupling Specifications Thomas Coupling Size Minimum SN226 0.09mm) 0.127mm) 0. (5.95 kg-m) 516 in-lb.005 in.005 in.127mm) 516 in-lb (5. (11.005in. (15.127mm) Angular (Maximum) 0.625 in. (11.005 in (0.005 in.49mm) End Gap Operating Limits Total Indicator Reading Offset (Maximum) 0.531 in. (0.500 in (12.Instruction and Operation Manual Thomas SN Spacer Type Vertical & Horizontal Coupling Specifications Table 7.438 in.72 kg-m) Bolt Torque 55 . (15.594 in.70mm) Maximum 0. (0.13mm) SN312 0.500 in. (0.469 in. (11. (0.127mm) 0.127mm) 0.70mm) 0. (13.91mm) Normal 0. (12.005 in.

A & B Demulsibility ASTM D 1401 Minutes to 0 ml emulsion At 54°C (130°F) after 30 min. ASTM D 892 Sequence 1 Sequence 2 Sequence 3 Note: No other additives are recommended. 204 (400) min.2 (44 min. Pass Pass 1 to 5 0. 25/0 max. At 82°C (180°F) after 60 min. SSU @ 210°F 95 minimum 32 56 .20 Pass 28 – 37 -7 (20) max.Instruction and Operation Manual Gearbox Lube Oil Specifications Table 8.8 to 35.Number. Maximum ASTM D 1500 Neut. 50/0 max. 25/0 max. 28.2 (150/180 SSU @ 100°F) 5. Index ISO Viscosity Grade Color. °C (°F) Viscosity. CST at 100°C Viscosity. °C (°F) Flash Point. Maximum Rust Protection ASTM D 665. cST at 40°C Viscosity. Foam Limits. Gearbox Lube Oil Specifications Recommended Gearbox Lube Oil Specifications API Gravity Pour Point.

1 1 1 1 1 1 1 2 1 *1 1 1 1 1 *1 *1 1 1 1 1 1 1 1 1 1 *1 *1 1 1 Item No. Gearbox Parts List Item No. 23A 51D 60C 98 101A 101B 102 105 110 115 A120 120 122A 123A 125C 125D A130 130 132B 133B A140 140 122C 123B 123C 125A 125B 132C 151A Part Name Lube Pump Spring Seal Rotating Face Mechanical Seal Dust Cover (For Coupled Shaft Only) Gearbox Housing (Output) Gearbox Housing (Input) Bearing Plate Housing Gasket Interconnecting Shaft Shaft Seal Low Speed Shaft Assembly Low Speed Shaft Spur Gear (Low Speed) Shaft Spacer (Low Speed) Ball Bearing Ball Bearing High Speed Shaft Assembly High Speed Shaft Pinion Gear (High Speed) Thrust Runner Idler Shaft Assembly Idler Shaft Spur Gear (Idler) Shaft Spacer (Idler) Shaft Spacer (Idler) Ball Bearing Ball Bearing Pinion Gear Journal Bearing or Tilting Pad Qty. 173 174A 174B 174C 174D 177 180 185 186 191 193C 905E 905H 905M 905N 909B 909C 914E 914F 916A 916D 916H 961J 918D 920A 920B 920C 920D 920F Part Name Tube (Sump) Lube Jet Lube Jet Lube Jet Lube Jet Valve Filter Manifold Oil Filter (FRAM PH-41) Fill and Vent Fitting Sight Glass Pressure Gage Hex Head Cap Screw Hex Head Cap Screw Hex Head Cap Screw Hex Head Cap Screw Bolt Bolt (alignment) Hex Nut Hex Nut (Alignment) Washer Washer Washer Washer (alignment) Pin Key Key Key Key Key (For Coupled Shaft Only) Qty. 1 1 1 1 1 1 1 *1 1 1 1 3 2 3 3 7 2 7 2 3 2 14 4 1 1 1 1 1 1 57 .Instruction and Operation Manual Gearbox Parts List Table 9.

Part Name Journal and Thrust Bearing Assembly (Lower) 151B Journal Bearing or Tilting Pad Journal and Thrust Bearing Assembly (Upper) 154D 154E 155A Lock Washer (Lower) Lock Washer (Upper) Thrust Washer (Lower) – required with Journal Bearing Thrust Washer (Upper) – required with Journal Bearing Shim Spacers Lube Pump 3 3 1 1 Qty. 1 1 2 2 2 2 As Required Tube *Available in sets of five 0.005 inch (0.Instruction and Operation Manual Item No. 924AA 924E 924G 924H 924K 936K 936M 936N 936T 1 944a 944b AR *1 947A 951Y Pipe Plug Pipe Plug Pipe Plug Pipe Plug Pipe Plug O-ring Packing O-ring Packing O-ring Packing O-ring Packing Pipe Connector (Female) Pipe Connector (Male) Elbow Nipple Part Name Qty.13mm). 1 1 1 1 1 1 *2 *2 *2 1 1 1 1 155B 158 160 *Recommended Spare Parts Gearbox Replacement Parts Table 10. 185 115 105 936M 936N 936T 158 Series MP01AA10 Part Name Gearbox Oil Filter Input Shaft Lip Seal Housing Gasket O-ring Packing O-ring Packing O-ring Packing * Shim Spacers Anti-fretting Compound Qty.010 inch (0. 0.25mm) 58 . Item No. Gearbox Replacement Parts Item No.

20 x ¾ ¾ .102 in-lbs (11 .24 x 1 ¼ .54 N-m) 95 .102 in-lbs (11 . Spacer Throttle Bushing/Mechanical Seal Double Seal with Spacer Case Nuts Seal Housing to Gearbox Separator ½ .0 .12 N-m) Note: When using PTFE o-rings.9.5 N-m) 75-80 in-lbs (8.5 N-m) Pump Item No.12 N-m) 95 .0 N-m) 60-65 ft-lbs (81 . 3 905E 905F 905G 914A -905P Location Impeller Bolt/Inducer Mechanical Seal No.0 N-m) 35-40 in-lbs (4.4.13 x 4 5/8 .102 in-lbs (11 .12 N-m) 250-275 ft-lbs (340 . Repeat until there is no change in torque value.88 N-m) 60-65 ft-lbs (81 .20 x ½ #10 .Instruction and Operation Manual Gearbox and Pump Torque Values Table 11.16 x 1 ¾ ¼ .12 N-m) 95 .40 ft-lbs (48 .54 N-m) 95 .102 in-lbs (11 .5 . allow 15 minutes between repeated torquing for the PTFE to cold flow.2.20 x 5/8 Torque Value 36 .20 x 12 ¼ .20 x 12 ¼ .N 905T 909B 909C Location Oil Filter Manifold Gearbox Seal Journal Bearings Chemical Barrier Gasket Gearbox Halves Gearbox Halves. Alignment Sight Glass Size 3/8 .20 Size ¼ . 905H 905L 905M.20 x 5/8 ½ .9.88 N-m) 20-22 in-lbs (2. 59 .10 3/8 .18 x 4 17/64 #8 .32 x 1/2 Torque Value 22-25 ft-lbs (30 .16 x ½ ¼ .34 N-m) 75-80 in-lbs (8.5 .370 N-m) 35 .3 . Gearbox and Pump Torque Values Gearbox Item No.40 ft-lbs (49 .

Mechanical Seals Item No. For additional information. To maximize seal performance consult the parts list for correct seal configuration. Item 60C to be used on gearbox only. please contact your area representative or the Sundyne factory direct. Lower Process Seal 60A 61A *62A *63A *64A 65A *68A *69A Upper Process Seal 60-B 61B 62B* 63B 64B* 65B* 68B* 69B* 60C 61C *62C N/A *64C *65C N/A *69C Mechanical Seal Assembly Seal Retainer Seal Face Washer Seal Spring Backup Ring Seal Retaining Ring Seal Spring Teflon Wedge Secondary may be “U” Cup or o-ring Gearbox Seal Description *Seal Repair Kits are Available and contain all parts marked with a single asterisk. 60 .Instruction and Operation Manual Mechanical Seals Table 12.

Instruction and Operation Manual 1 ½” gas seal for upper tandem position on light hydrocarbon service only Gearbox Seal Only 61 .

87A RKORP311 936A 936D 936E 936F 936G 936H 936J 936K 936P 936V 936Z Part Name Thermal Barrier Gasket O-ring Repair Kit for the pump end consisting of: • O-ring Packing • O-ring Packing • O-ring Packing • O-ring Packing • O-ring Packing • O-ring Packing • O-ring Packing • O-ring Packing • O-ring Packing • O-ring Packing • O-ring Packing Qty.Instruction & Operation Manual Pump Disassembly Replacement Parts Table 13. 1 See Seal Graphics Technical Seal Repair Kits High Seal Rotating faces: • Single • Tandem • Double • O-ring Packing • O-ring Packing 1 2 1 1 1 51A 51A/51C 51C 936B 936C 62 . Pump Disassembly Replacement Parts The following replacement parts will be required as a result of pump disassembly for maintenance as shown in this section: Item No.

911 914A 916B 916S 918A 924B 924D 936A 936B 936C 936D 936E 936F 936G 936H 936J 981 Stud Hex Nut Washer Washer Pin Pipe Plug Bull Plug O-ring Packing O-ring Packing O-ring Packing O-ring Packing O-ring Packing O-ring Packing O-ring Packing O-ring Packing O-ring Packing Baffle Plate Part Name Qty 12 12 3 4 1 1 1 *1 *1 *1 *1 *1 *1 *1 *1 *1 1 * Recommended spare parts 63 . Pump Parts List Item No. 1 2 3 4 5 9 10 13 14A 15 21B 30 50 51A 51C 87A 905A 905F Part Name Pump Casing Impeller Impeller Bolt Impeller Key Impeller Tab Washer Inducer (Optional) Inducer Stud (Optional) Diffuser Locating Pin Diffuser Cover Throttle Bushing Seal Housing Slinger Sleeve Assembly Seal Rotating Face Seal Mating Ring Spacer (or Thermal Barrier Gasket) (Large) Hex head Cap Screw Hex Head Cap Screw Qty 1 1 1 *1 *1 1 1 1 2 1 1 1 1 *1 *1 1 3 3 Item No.Instruction and Operation Manual Pumps Parts List Table 14.

Seal Spring . Double Seal Arrangement Table 15.Seal FAce Washer .Retainer & Drive Sleeve Assembly .Seal Retaining Ring .Seal Spring Back-Up Disc .Seal Wedge Ring 1 *1 *1 *1 1 *1 1 **1 **1 **1 **6 **1 60B 61B 62B 63B 64B 65B 68B 905F 916B 936H 936J Mechanical Seal (Upper) .Seal Spring .Seal Face Washer .Retainer & Drive Sleeve Assembly . 19A 50A 50B 51C 52 60A 61A 62A 63A 64A 65A 68A PART NAME QTY ITEM NO. Double Seal Arrangement ITEM NO.Seal Wedge Ring Hex Head Cap Screw Washer O-ring Packing O-ring Packing *1 1 **1 **1 **1 **6 **1 3 3 *4 *2 Part Name QTY * Recommended Spare Parts **Recommended Seal Spare Component Parts 64 .Seal Spring Back-Up Disc . Seal Retaining Spacer Shaft Sleeve (Lower) Shaft Sleeve (Upper) Seal Rotating Face Seal Spacer Mechanical Seal (Lower) .Seal Retaining Ring .Instruction and Operation Manual Double Seal Arrangement and Parts Figure 12.

Instruction and Operation Manual Single Seal Arrangement and Parts Figure 13. Single Seal Arrangement Item No. Single Seal Arrangement Table 16. 3 3 3 3 *2 *1 *1 *1 *Recommended Spare Parts 65 . 1 *1 *1 *1 *1 *1 3 3 Item No. 21B 50 51A 51D 60A 60C 905E 905F Part Name Upper Throttle Bushing Slinger Sleeve Assembly Seal Rotating Face Seal Rotating Face (Gearbox) Mechanical Seal (Lower) Mechanical Seal (Gearbox) Hex Head Cap Screw Hex Head Cap Screw Qty. 905L 916A 916B 916K 936H 936J 936K 936P Part Name Hex Head Cap Screw Washer Washer Washer O-ring Packing O-ring Packing O-ring packing O-ring Packing Qty.

Tandem Seal Arrangement Table 17. 3 3 3 3 *2 *1 *1 *1 *Recommended Spare Parts 66 . 21B 50 51A 51D 60A 60C 905E 905F Part Name Upper Throttle Bushing Slinger Sleeve Assembly Seal Rotating Face Seal Rotating Face (Gearbox) Mechanical Seal (Lower) Mechanical Seal (Gearbox) Hex Head Cap Screw Hex Head Cap Screw Qty. 1 *1 *1 *1 *1 *1 3 3 Item No.Instruction and Operation Manual Tandem Seal Arrangement and Parts Figure 14. 905L 916A 916B 916K 936H 936J 936K 936P Part Name Hex Head Cap Screw Washer Washer Washer O-ring Packing O-ring Packing O-ring packing O-ring Packing Qty. Tandem Seal Arrangement Item No.

Instruction and Operation Manual Separator Arrangements Figure 15. Separator Arrangements 67 .

Pump and Gearbox Cross Section 68 .Instruction and Operation Manual Pump and Gearbox Cross Section (Single Seal Arrangement) Figure 16.

Exploded View 69 . Gearbox .Instruction and Operation Manual LMV-311 Gearbox (Exploded View) Figure 17.

Instruction and Operation Manual Pump Casing and Seal Housing (Exploded View) Figure 18. Pump Casing and Seal Housing (Exploded View) 70 .

Instruction and Operation Manual Gaskets Figure 19. Chemical Barrier Gasket (option) Figure 20. Flexitallic Gasket (option) 71 .

14 Operation of Sundyne Pumps. 7 Installation and Start-Up Checklist. 2 Control Checklist. 7 Suction and Discharge Piping. 12 Gearbox Lube Oil Specifications. 2 Pump and Gearbox Cross Section (Single Seal Arrangement). 16 Single Seal Arrangement and Parts. 63 Reassembly. 67 Setting Pump Valves. 17 Parallel Operation. 17 Environmental Control System. 5 ISO 9001. 4 Gearbox Sump. 10 Check Driver Rotation. 3 Pressurizing Fluid Loop. 3 Auxiliary Lube Pump. 12 Oil Pressure. 10 Driver Instructions. 4 Preventative Machine Guards. 3 Equipment and Safety. 2 Flexible Coupling for LMV Units Without a Vertical Stand. 33 Remote Heat Exchanger. 3 Electrical Safety. 2 72 . 60 Minimum Flow Conditions. 3 Main Lube Pump and Lube Oil Priming Kit. 4 High-Speed Shaft. 2 Text Symbols. 13 Sundyne Centrifugal Pumps. 62 Pump Mechanical Seal Diagnostics. 4 Shaft Sleeve. 1 Thomas SN Spacer Type-Vertical & Horizontal Specifications. 17 SundGard™ Oil Filter. 65 Specifications. 17 Mounting Vertical Units with Stands (LMV). Cleaning and Repair. 19 Double Seal Arrangement and Parts. 7 Storing Your Pump Short-Term. 54 Troubleshooting. 4 Controlling the Pump During Startup. 15 Storing Your Pump Long-Term. 19 Mechanical Seals. 3 Pre-Commission Checklist. 56 Gearbox Mechanical Seal. 13 Seal Environmental Control System. 14 Maintenance.Instruction and Operation Manual INDEX Auxiliaries. 49 Using Forklifts. 13 Heat Exchanger. 12 Machine Familiarization. 53 Falk Double Gear Type-Vertical Specifications. 8 Suction Conditions. 47 Index. 7 Inspection. 4 Bearing and Shaft Clearances. 2 Entrained Gases. 53 Start-Up Procedures. 66 Testing Equipment. 3 Check Operating Procedures. 55 Thomas Type DBZ Coupling Specifications. 53 Fall Protection. 9 Oil Manifolds. 31 Inspection. 3 Falk Double Gear Type Specifications. 4 Chemical Use. 17 Tandem Seal Arrangement and Parts. 18 Personal Protective Equipment. 31 High-Speed Shaft Endplay. 54 Falk Steelflex Type Coupling Specifications. 16. 64 Driver and Coupling. 69 Lube System. 1 Liquid Buffer System. 57 Gearbox Replacement Parts. 13 Gearbox Sump Heater. 32 BMP Units. 51 Pumps Parts List. 11 Gaskets. 10 Mounting Vertical Units Without Stands. 72 Inspecting All Bearings. 68 Pump Disassembly Replacement Parts. 16 Disassembly of LMV-311. 31 Gearbox Parts List. 9 LMV-311 Gearbox (Exploded View). 2 Piping Connections. 13 Gearbox & Pump Diagnostics. 32 Single Operation. 1 System Head Curve. 59 Gearbox Heat Exchanger. 1 Explosion/Fire Hazard. 71 Gearbox. 49 Gearbox and Pump Torque Values. 9 Separator Arrangements. 31 INSTALLATION. 58 Gearbox Servicing.

sundyne. 64th Avenue • Arvada. Colorado 80007 USA • +1-303-425-0800 • FAX: +1-303-425-0896 • www.com Sundyne Europe • Longvic Cedex • France • 011-33-3-80-383300 • FAX: 011-33-3-80-383371 ANSIMAG • ANYSPEED • CASTER • GSP • HMD/KONTRO • MASO/SINE • SCMP • SUNDYNE COMPRESSORS • SUNDYNE • SUNFLO .14845 W.

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