Maintenance Manual

2368.8000/A10-14 G2 (04/04/03.0) LCC

Slurry Pumps

LCC - Metal
LCC-Metal LCC - Rubber
LCC-Rubber

Pump Type:

Pump Serial Number:

Date:
Purchaser:
Purchaser’s Order Number:
GIW Work Order Number:
Shipped To:

Include the pump’s serial number when ordering replacement parts.

Note: This is a standard maintenance manual provided for your convenience. GIW is in the process
of developing a custom maintenance manual for your particular pump order or has shipped it to an
alternate address as requested on the order. If you or the alternate addressee do not receive the
custom manual, please contact GIW Sales at (706) 863-1011 ext. 2423 or email
www.sales@giwindustries.com.

This manual may not be reproduced without written consent of GIW Industries. Additional copies
may be purchased. Please contact your sales representative for details.

GIW INDUSTRIES, INC. KSB AG KSB S.A.

5000 Wrightsboro Road Bahnhofplatz 1 10/14, rue de la Gare
Grovetown, GA 30813 USA D-91257 Pegnitz, GERMANY F-76250 Déville-lès-Rouen, FRANCE

(706) 863-1011 (0 92 41) 71-0 32 82-32 00

FAX (706) 855-5151 FAX (0 92 41) 71-17 91 FAX 32 82-32 90

A KSB Company
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Contents
Page
6.3.2 Measures to be taken for Prolonged
1 General 4 Shutdown 13
2 Safety 4 6.3.3 Storage of Elastomer Linings 14
2.1 Marking of Instructions in the Manual 4 6.4 Returning to Service after Storage 14
2.2 Personnel Qualification and Training 4 7 Maintenance /Repair 14
2.3 Non-compliance with Safety Instructions 4 7.1 General Instructions 14
2.4 Safety Awareness 4 7.2 Maintenance / Inspection 14
2.5 Safety Instructions for the Operator / User 5 7.2.1 Supervision of Operation 14
2.6 Safety Instructions for Maintenance, 7.2.2 Lubrication and Lubricant Change 14
Inspection and Installation 5 7.2.2.1 Lubrication 14
2.7 Unauthorized Modification and Manufacture of 7.2.2.2 Grease Quality / Grease Changes 14
Spare Parts 5 7.2.2.3 Oil Changes 15
2.8 Unauthorized Modes of Operation 5 7.3 Drainage / Disposal 15
3 Transport and Interim Storage 5 7.4 Dismantling 14
3.1 Transport 5 7.4.1 Sectional Drawings and Bills of Material 15
3.2 Short Term Storage 5 7.4.2 Dismantling Procedures 15
4 Description of the Product andAccessories 6 7.5 Reassembly 16
4.1 Technical Specification 6 7.5.1 General Instructions 16
4.2 Designation 6 7.5.2 Mounting of Bearings 17
4.3 Design Details 6 7.5.3 Inserting Shaft and Bearings into Housing 17
4.3.1 Pump Casing 6 7.5.4 Installing End Covers and Seals 17
4.3.2 Impeller Form 6 7.5.5 Mounting Shaft Sleeve 18
4.3.3 Shaft Seal 6 7.5.6 Mounting Stuffing Box 18
4.3.4 Bearings 8 7.5.7 Mounting the Bearing Assembly to Pedestal 18
4.3.5 Permissible Forces and Moments at the Pump 7.5.8 Metal Expeller Assembly 18
Nozzles 9 7.5.9 Mounting Shell 19
4.3.6 Noise Characteristics 9 7.5.10 Elastomer Lined Wet End 19
4.4 Accessories 9 7.5.11 Impeller 19
4.5 Dimensions and Weights 9 7.5.12 Suction Plate and Liner ( LCC-H only) 19
5 Installation at Site 9 7.5.13 Axial Adjustment of the Bearing Housing 19
5.1 Safety Regulations 9 7.5.14 Expeller Running Clearance 20
5.2 Foundation 10 7.5.15 Tightening Torques 20
5.3 Installing the Pump / Unit 10 7.5.16 Mounting the Gland Packing 20
5.3.1 Aligning the Pump / Drive Train 10 7.6 Spare Parts Stock 21
5.3.2 Place of Installation 11 7.6.1 Maintenance Procedures for Maximum Parts
5.4 Connecting the Piping 11 Life 21
5.4.1 Auxiliary Connections 11 7.7 Operational Problems and Solutions 21
5.4.2 Safety Guards 11 8 Trouble Shooting 23
5.5 Final Check 11 8.1 Low Flow Rate 23
5.6 Connection to Power Supply 11 8.2 Bearing Temperature
6 Commissioning, Start-up / Shutdown 11 8.3 Bearing Contamination 23
6.1 Commissioning 11 8.4 Stuffing Box 23
6.1.1 Lubricants 11 8.5 Over Heating of Pump Casing 23
6.1.2 Shaft Seal 12 8.6 Pump Leakage 23
6.1.3 Priming the Pump and Other Checks 12 8.7 Motor Overload 23
6.1.4 Checking the Direction of Rotation 12 8.8 Vibrations or Abnormal Noises 23
6.1.5 Cleaning the Plant Piping 12 9. Torque Chart 24
6.1.6 Suction Strainer 12
6.1.7 Start-up 13 NOTES 25
6.1.8 Shutdown 13 10 General Drawing with List of
6.2 Operating Limits 13 Component 26
6.2.1 Temperature of the Medium Handled, Ambient 11 Supplements 26
Temperature, Bearing Temperature 13 11.1 Throat Bushing Option 26
6.2.2 Switching Frequency 13 11.2 Duo Cone Seal Option 27
6.2.3 Density of the Medium Handled 13 11.3 Underwater Pump Operation 29
6.3 Shutdown / Storage / Preservation 13
6.3.1 Storage of New Pumps 13
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Index
Section Page Section Page

Accessories 4.4 9 Operation, Unauthorized modes 2.8 5

Aligning the Pump / Drive Train 5.3.1 10 Operational Problems and Solutions 7.7 21
Bearing Assembly Clamp Bolts 7.5.15 20 Packing the gland 7.5.16 20
Bearing Assembly, mounting 7.5.7 18 Personnel Qualification and Training 2.2 4
Bearing Housing, Axial Adjustment of 7.5.13 19 Piping System Design 7.7 22
Bearing, Taper Locknut Assembly Torque 7.5.15 20 Piping, Allowable Forces and Moments 4.3.5 9
Bearings 4.3.4 8 Piping, Cleaning the Plant 6.1.5 12
Bearings, mounting 7.5.2 17 Piping, Connecting the 5.4 10
Bills of Material 7.4.1 15 Power Supply, Connection 5.6 11
Casing 4.3.1 6 Priming the Pump and Other Checks 6.1.3 12
Cavitation / NPSH Performance 7.7 22 Reassembly , General Instructions 7.5.1 16
Check, Final 5.5 11 Reassembly 7.5 16
Commissioning 6.1 11 Rotation, Direction of 6.1.4 12
Commissioning, Start-up / Shutdown 6 11 Safety 2 4
Connections, Auxiliary 5.4.1 11 Safety Awareness 2.4 4
Density of the Medium Handled 6.2.3 13 Safety Instructions for the Operator / User 2.5 4
Description of the Product and Accessories 4 6 Safety Instructions, for Maintenance 2.6 5
Design Details 4.3 6 Safety Instructions, Non-compliance with 2.3 4
Designation 4.2 6 Safety Regulations 5.1 9
Dimensions 4.5 9 Seal Water Requirements 7.5.16 21
Dismantling 7.4 15 Shaft Seal 4.3.3 6
Drainage / Disposal 7.3 15 Shaft Seal, Commissioning 6.1.2 12
Drawing / List of Components 9 26 Shaft Sleeve, mounting 7.5.5 18
Drawings , Sectional 7.4.1 15 Shaft, insertion into Housing 7.5.3 17
Elastomer Lined Wet End, assembly 7.5.10 19 Shell, mounting 7.5.9 19
End Covers and Seals, installation 7.5.4 17 Shell, parts life 7.6.1 21
Expeller Running Clearance, 7.5.14 20 Shutdown / Storage / Preservation 6.3 13
Expeller, metal assembly 7.5.8 18 Shutdown 6.1.8 13
Foundation 5.2 10 Shutdown, Prolonged 6.3.2 13
General 1 4 Spare Parts Stock 7.6 21
Grease Quality / Grease Changes 7.2.2.2 14 Spare Parts, Unauthorized Modification of 2.7 5
Guards, 5.4.2 11 Specifications 4.1 6
Impeller Dismantling 7.4.2 15 Start-up 6.1.7 13
Impeller Form 4.3.2 6 Start-up Strainer 6.1.6 12
Impeller Lifting Jig 7.4.2 15 Storage of Elastomer Linings 6.3.3 14
Impeller, mounting 7.5.11 19 Storage of New Pumps 6.3.1 13
Impeller, parts life 7.6.1 21 Storage, Returning to Service after 6.4 14
Installation 5.3.2 10 Storage, /Short term 3.2 5
Installation at Site 5 9 Stuffing Box, mounting 7.5.6 18
Installing the Pump / Unit 5.3 10 Suction Liner, parts life 7.6.1 21
Lubricants 6.1.1 11 Suction Plate and Liner ( LCC-H only) 7.5.12 19
Lubrication 7.2.2.1 14 Sump Design 7.7 21
Lubrication and Lubricant Change 7.2.2 14 Switching Frequency 6.2.2 13
Maintenance / Inspection 7.2 14 Temperature, of Medium Handled, Ambient 6.2.1 13
Maintenance /Repair 7 14 Tightening Torques 7.5.15 20
Maintenance, General Instructions 7.1 14 Transport 3.1 5
Marking of Instructions in the Manual 2.1 4 Transport and Interim Storage 3 5
Noise Characteristics 4.3.6 9 Trouble Shooting 8 23
Oil Changes 7.2.2.3 15 Wear Problems and Solutions 7.7 21
Operating Conditions of Flow and Head 7.7 22 Wear, Parts Life 7.6.1 21
Operating Limits 6.2 13 Weights 4.5 9
Operation, Supervision of 7.2.1 14

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1 General
The word
Caution
This manual contains important information
for reliable, proper and efficient operation. Compliance with
Caution
is to introduce safety instructions whose non-observance
the operating instructions is of vital importance to ensure
may lead to damage to the machine and its functions.
reliability and long service life of the pump, and to avoid any
risks.
Instructions attached directly to the machine, such as:
• Arrow indicating the direction of rotation
These operating instructions do not take into account local
regulations; the operator must ensure that such regulations • Marking for fluid connections
are strictly observed by all, including the personnel called in must always be complied with and be kept in legible
for installation. condition at all times.

This pump / unit must not be operated beyond the limit 2.2 Personnel Qualification and Training
values specified in the technical documentation for the All personnel involved in the operation, maintenance,
medium handled, capacity, speed, density, pressure, inspection and installation of the machine must be fully
temperature and motor rating. Make sure that operation is in qualified to carry out the work involved.
accordance with the instructions given in this manual or in
the contract documentation. Personnel responsibilities, competence and supervision
must be clearly defined by the operator. If the personnel in
The nameplate indicates the type series / size, main question are not already in possession of the requisite know-
operating data and serial number; please quote this how, appropriate training and instruction must be provided.
information in all queries, repeat orders and particularly If required, the operator may commission the manufacturer /
when ordering spare parts. supplier to provide such training. In addition, the operator is
responsible for ensuring that the contents of the operating
If you need any additional information or instructions instructions are fully understood by the responsible
exceeding the scope of this manual or in case of damage personnel.
please contact your GIW / KSB representative.
2.3 Non-compliance with Safety Instructions
Non-compliance with safety instructions can jeopardize the
safety of personnel, the environment and the machine itself.
2 Safety Non-compliance with these safety instructions will also lead
These operating instructions contain fundamental to forfeiture of any and all rights to claims for damages.
information that must be complied with during installation,
operation and maintenance. Therefore this operating In particular, non-compliance can, for example, result in:
manual must be read and understood both by the installing • Failure of important machine / unit functions
personnel and the responsible trained personnel / operators • Failure of prescribed maintenance and servicing
prior to installation and commissioning, and it must always practices
be kept close to the operating location of the machine / unit
• Hazard to persons by electrical, mechanical and
for easy access. chemical effects
• Hazard to the environment due to leakage of hazardous
Not only must the general safety instructions given in this
substances.
chapter of “Safety” be complied with, but also the safety
instructions outlined under specific headings.
2.4 Safety Awareness
It is imperative to comply with the safety instructions
2.1 Marking of Instructions in the Manual
contained in this manual, the relevant national and local
The safety instructions contained in this manual whose non-
health and safety regulations and the operator’s own internal
observance might cause hazards to persons are specially
work, operation and safety regulations.
marked with the general hazard sign, namely
2.5 Safety Instructions for the Operator / User
• Any hot or cold components that could pose a hazard
must be equipped with a guard by the operator.
safety sign in accordance with DIN 4844-W9. • Guards that are fitted to prevent accidental contact with
moving parts (e.g. coupling) must not be removed while
The electrical danger warning sign is the machine is operating.
• Leakages (e.g. at the shaft seal) of hazardous media
handled (e.g. explosive, toxic, hot) must be contained so
as to avoid any danger to persons and the environment.
safety sign in accordance with DIN 4844-W8. Pertinent legal provisions must be adhered to.
• Electrical hazards must be eliminated. (Refer to the
relevant safety regulations applicable to different
countries and / or the local energy supply companies.)

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2.6 Safety Instructions for Maintenance, Inspection Figures below give suggested lifting methods. Actual safe
and Installation lifting method will vary with pump configuration and type of
The operator is responsible for ensuring that all lifting equipment. Ensure secure attachments and test lifting
maintenance, inspection and installation work is performed method for stability before moving pump.
by authorized and qualified personnel who are thoroughly Fig. 3.1-1 Transport of the pump
familiar with the manual.

Work on the machine must be carried out only during

standstill. The shutdown procedure described in the manual
for taking the machine out of service must be adhered to
without fail.

Pumps or pump units handling media injurious to health

must be decontaminated.

Immediately following completion of the work, all safety /

protective devices must be re-installed and / or re-activated.

Please observe all instructions set out In the chapter on

“Commissioning” before returning the machine to service.

2.7 Unauthorized Modification and Manufacture of

Spare Parts
Modifications or alterations of the machine are only
permitted after consultation with the manufacturer. Original
spare parts and accessories authorized by the manufacturer
ensure safety. The use of other parts can invalidate any
liability of the manufacturer for damage or warranty.

2.8 Unauthorized Modes of Operation

Any warranty of the operating reliability and safety of the
pump / unit supplied is only valid if the machine is operated
in accordance with its designated use as described in the
following sections. The limits stated in the data sheet must
not be exceeded under any circumstances.

3 Transport and Interim Storage

3.1 Transport
Proper lifting and safety practices must be observed at all
times. Lifting the pump assembly requires extreme care,
since the center of gravity is not located in the physical
center of the unit, but is usually closer to the stuffing box /
shaft seal area. WARNING: Very top heavy
Fig. 3.1-2 Transport of the complete unit
Never lift by a single point and do not use the pump or motor
shaft as a lift point. Eyebolt locations on the bearing
assembly and motor are intended for lifting those items only 3.2 Short Term Storage
and must not be used to lift the pump assembly. The pump / unit should be stored in a dry room where the
atmospheric humidity is as constant as possible.
At least four (4) connections are recommended to stabilize
the load, and they should be as far apart as practical. Avoid If stored outdoors, the unit and crates must be covered by
excessive side loads on cast lifting eyes. Note that certain waterproof material to avoid any contact with humidity.
lift points on the pedestal are intended for use in handling
the pedestal alone and are not necessarily optimum balance All openings of the assembled pump / unit components are
points for the pump assembly. closed and must only be opened when required during
installation.
Always make sure that the unit remains in the horizontal
position during transport and cannot slip out of the transport Caution
suspension arrangement. Protect all stored goods against humidity,
dirt, vermin and unauthorized access!
If the pump / unit slips out of the suspension
arrangement, it may cause personal injury and damage to See Section 6.3 for long term storage requirements.
property.

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4 Description of the Product and 3 Extra Heavy Hard Metal. Similar to hard metal version,
but with heavier sections and hydraulics suited to the most
Accessories severe slurry duties. Two-stage pressure capability.
4.1 Technical Specification Available in sizes LCC 150 - 500 and above.
Centrifugal pump for handling coarse or fine particles from
solids-laden waste water to aggressive slurries of an All casings carry 125 pound, ANSI flange bolting patterns.
abrasive or corrosive nature. Adapters for conversion to DIN flanges are available.
Applications include process pumping and tailings disposal
for mining, dredging and other industrial operations.
4.2 Designation
LCC-R 200-600.4 P
Pump Type
Hydraulic Type
Discharge Nozzle DN in mm
Nominal Impeller Diameter in mm
Mechanical Size
Seal Type
Hydraulic Type
M ............................................ Metal
R............................................. Elastomer
Figure 4.3-1 LCC Hard Metal Wet
H............................................. Extra-Heavy Construction
O ............................................ Open Metal Impeller
Mechanical (Frame) Size
1 2 3 4 5
35 mm 50 mm 70 mm 100 mm 125 mm

Seal Type
P ........................................... Packing
M .......................................... Mechanical Seal
E ........................................... Expeller
Nominal Flange and Impeller Diameters in mm (inches)
Designation Discharge Suction Impeller
LCC 50 - 230 50 ( 2” ) 80 ( 3” ) 225 ( 8.86” )
LCC 80 - 300 80 ( 3” ) 100 ( 4” ) 310 ( 12.22”)
LCC 100 - 400 100 ( 4” ) 150 ( 6” ) 395 ( 15.55”)
LCC 150 - 500 150 ( 6” ) 200 ( 8” ) 500 ( 19.69” ) Figure 4.3-2 LCC Elastomer-Lined Wet End
LCC 200 - 610 200 ( 8” ) 250 ( 10”) 610 ( 24” )
LCC 250 - 660 250 ( 10”) 300 ( 12”) 660 ( 26” )
LCC 300 - 710 300 ( 12”) 350 ( 14”) 710 ( 27.95”)

4.3 Design Details

Horizontal, end suction, modified volute casing pump with
three-vane impeller for large solids passage. Available in
interchangeable elastomer, metal and extra-heavy designs.
4.3.1 Pump Casing
Three standard configurations are available:

1 Hard Metal. Single-wall casing, impeller and suction

liner of high-chrome white iron. Suitable for high-discharge
head, all particle sizes up to maximum sphere passage and Figure 4.3-3 LCC Extra Heavy Hard Metal Wet End
mildly corrosive slurries. Custom materials available for
highly corrosive slurries. 4.3.2 Impeller Form
All standard impellers are 3 vane, double shrouded designs
2 Elastomer Lined. Radially split construction with ductile as seen in figures 4.3-1 through 4.3-3. Open-shrouded and
iron outer casing and molded-elastomer inner liners. alternate vane number designs are available in some sizes.
Impeller of high chrome white iron or polyurethane. For
moderate discharge head, fine to medium particles and 4.3.3 Shaft Seal
highly corrosive slurries. All standard pumps use replaceable gland packing in a
stuffing box with connections for flush water or sealing liquid.
Options include forward flush, slurry duty mechanical seals
or expeller with grease lubricated gland packing.

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Slurry SG – The Specific Gravity of the slurry should remain
below 1.35.

Solids – Slurries that could deposit scale on pump surfaces

should be avoided.

Flow rate – Stay between 0.5 and 1.3 times the Best
Efficiency Point (QBEP).

Flushing – Solids in the process flow can precipitate out

when the pump stops and build up in the expeller chamber.
Over time, this reduces efficiency and accelerates wear. The
system should always be purged with clear water for at least
15 minutes prior to stopping the pump. Starting the system
on clear water will help the expeller displace solids.

When the stuffing box does not have flush water, the
Fig 4.3-4 Gland Packing packing must be lubricated with grease or oil. Graphite
packing such as Tuf-Pak 400 is recommended. Manual or
automatic grease dispensers are available depending on the
application. Twisting the cap in on the manual units will add
a small amount of grease to the packing. These are refilled
by removing the cap and packing the cup with lubricant.
Automatic greasers use a spring driven piston to maintain a
steady supply of grease. These are refilled by connecting a
grease gun to the fitting on the side of the unit. Note that
extremes in temperature can alter the amount of lubricant
supplied to the packing and must be accounted for.

New expeller pumps are equipped with a diverter ring

pressed into the hub area of the pump casing. This acts as a
baffle to help reduce the amount of solids entering the seal
chamber. The diverter can be ordered as a service part and
retrofit into earlier units.

It is important to operate the expeller pump within the speed

Fig 4.3-5 Expeller Seal with Grease Purged Packing
limitations and operating conditions specified in the original
design parameters. Wide variations in flow rate and solids
can allow particles to accumulate in the expeller chamber,
Expeller seals are used in pump applications where gland which may result in a plugging or premature component
flush water is not readily available or where it is not failure. Any change in the operating conditions should be
compatible with the process fluid. A second rotating impeller discussed with your GIW / KSB representative to establish if
contained in a separate casing creates a lower pressure at the new conditions are suitable for the equipment.
the stuffing box seal area. This allows the shaft sleeve to be
grease lubricated and run with only enough packing
compression to seal the pump.

Unlike mechanical seals, expellers must be designed for

each application and specific operating conditions. The GIW
Technical Manual contains the graphs and information
needed to select the right components for the pump.
Expellers require additional driver horsepower, which must
be accounted for during motor selection. Changes to head,
flow, process solids or sump level after the pump has been
installed can affect the functionality of an expeller sealing
system.

Correct installation, adjustment and operating procedures

are extremely critical to the proper function and life of these
seals Extensive testing has shown that the following
guidelines can help keep the expeller system operating Fig 4.3-6 Typical Slurry Mechanical Seal
properly while prolonging the life of wear components. For information on mechanical seals, consult the
manufacturer’s manual.
Particle size – The D50 should be kept between 200 and
1500 microns.

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4.3.4 Bearings Bearing Bearings Installed
The bearing assembly is a cartridge design mounted on a Assembly Spherical Double row, Taper roller
concentric pedestal with an adjustment mechanism for roller Part number Bench
setting the impeller axial clearance. E Type Cone / Cup / end-play
Spacer 1) mm (inch)
Standard lubrication is grease. Oil lube is also available. 35 mm 22209 E 53177 / 53376D 0.15
For lubrication quality and quantity, see Section 7.2. / X2S53176 (.006)
50 mm 22212 E 72225C / 0.15
Basic bearing parts are listed for reference. Note that the suffix can 72488D / (.006)
vary depending on configuration and vendor. Replacement bearings
X1S72225
are available from GIW/KSB.
70 mm 22217 E 9285 / 9220D / 0.18
X4S9285 (.007)
100 mm 22224 E HM926740 / 0.25
HM926710CD/ (.010)
HM92674XA
125 mm 22230 E HH932145 / 0.20
2) HH932110 / (.008)
H932145XA
1) Timken Co. part numbers shown, Koyo is also an approved
supplier.
2) 125 mm taper roller bearing assembled from two single row
bearings. Other sizes are TDO (one piece cup) design.

Fig 4.3-7 Cartridge Bearing Assembly

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4.3.5 Permissible Forces and Moments at the
Pump Nozzles
The forces and moments are according to a modified version
of French Standard NF E 44-145. The data on forces and
moments apply to static pipelines only. The values are only
applicable if the pump is installed on a completely grouted
base plate and bolted to a rigid and even foundation.

Pump Allowable Forces N ( lbs. ) Allowable Moments N-m ( ft-lbs. )

Flange Fx Fy Fz Mx My Mz
50mm 600 700 500 120 100 80
( 2 in.) ( 135 ) ( 160 ) ( 110 ) ( 90 ) ( 75 ) ( 60 )
75mm 900 1000 800 230 190 160
(3 in.) ( 200 ) ( 225 ) ( 180 ) ( 170 ) ( 140 ) ( 120 )
100mm 1200 1350 1050 380 310 260
(4 in.) ( 270 ) ( 305 ) ( 235 ) ( 280 ) ( 230 ) ( 190 )
Discharge 150mm 1800 2000 1600 750 610 520
(6 in.) ( 405 ) ( 450 ) ( 360 ) ( 555 ) ( 450 ) ( 385 )
Pipe 200mm 2400 2700 2100 1200 1000 850
(8 in.) ( 540 ) ( 610 ) ( 470 ) ( 885 ) ( 750 ) ( 630 )
250mm 3000 3350 2700 1800 1450 1250
(10 in.) ( 675 ) ( 750 ) ( 600 ) ( 1330 ) ( 1070 ) ( 920 )
300mm 3600 4000 3200 2400 2000 1700
(12 in.) ( 810 ) ( 900 ) ( 720 ) ( 1770 ) ( 1475 ) ( 1250 )
75mm 1000 800 900 230 190 160
(3 in.) ( 225 ) ( 180 ) ( 200 ) ( 170 ) ( 140 ) ( 120 )
100mm 1350 1050 1200 380 310 260
(4 in.) ( 305 ) ( 235 ) ( 270 ) ( 280 ) ( 230 ) ( 190 )
Suction 150mm 2000 1800 1600 750 610 520
(6 in.) ( 450 ) ( 405 ) ( 360 ) ( 555 ) ( 450 ) ( 385 )
Pipe 200mm 2700 2100 2400 1200 1000 850
(8 in.) ( 610 ) ( 470 ) ( 540 ) ( 885 ) ( 750 ) ( 630 )
250mm 3350 2700 3000 1800 1450 1250
(10 in.) ( 750 ) ( 600 ) ( 675 ) ( 1330 ) ( 1070 ) ( 920 )
300mm 4000 3200 3600 2400 2000 1700
(12 in.) ( 900 ) ( 720 ) ( 810 ) ( 1770 ) ( 1475 ) ( 1250 )
350mm 4650 3750 4200 3100 2550 2200
(14 in.) ( 1045 ) ( 845 ) ( 945 ) ( 2290 ) ( 1880 ) ( 1620 )

4.3.6 Noise Characteristics 4.5 Dimensions and Weights

If running within the normal limits of operation and on clear Dimensions and weights are listed on the pump
liquid, the sound pressure level for the pump alone does installation plan.
not exceed 80 dB at one meter.
5 Installation at Site
The addition of coarse solids, froth or cavitating 5.1 Safety Regulations
conditions can significantly increase the noise levels in
both the pump and piping. If accurate noise levels are Electrical equipment operated in hazardous
required for these conditions, field-testing will be required. locations must comply with the applicable explosion
Sound pressure levels from motor and gear reducer must protection regulations. This is indicated on the motor
be added to the above in accordance with standard rating plate. If the equipment is installed in hazardous
acoustic formulas, taking into account the distance locations, the applicable local explosion protection
between units. For belt driven units, add an additional 2 regulations and the regulations of the test certificate
dB. supplied with the equipment and issued by the responsible
approval authorities must be observed and complied with.
4.4 Accessories The test certificate must be kept close to the location of
Couplings, pulleys, belts, motor mounts and/or base plates operation for easy access (e.g. foreman’s office).
may be provided. Refer to the bill-of-materials, data
sheets and/or drawings for further information.

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5.2 Foundation Straight edge
All structural work required must have been prepared in
accordance with the dimensions stated in the dimension
table / installation plan.
a b
The concrete foundation shall have sufficient strength for
the pump and be completely cured before installation. The
mounting surface must be flat and level. Anchor bolts must
be located according to the installation plan. This can be a
done when the concrete is poured, or by drilling holes in b
existing foundations and grouting the bolts in place.
5.3 Installing the Pump / Unit Gauge
Straight edge
After placing the base plate on the foundation, it must be Fig. 5.3-2: Aligning the coupling with the help of a gauge
leveled by shimming. Shims should be fitted between the and a straight-edge
base plate and the foundation itself; they should always be
inserted to the left and right of the foundation bolts and in The radial and axial deviation (tolerance) between the two
close proximity to these bolts. For a bolt-to-bolt clearance coupling halves should not exceed 0.1 mm (0.004 inch).
of more than 800mm (30 in.), additional shims should be
inserted halfway between the adjoining holes. All shims Improper alignment of the unit can cause damage to
must lie perfectly flush. both the coupling and the unit itself!

Insert the foundation bolts and set them into the For V-belt installations, the pulleys are correctly aligned if
foundation using concrete. When the mortar has set, a straight-edge placed vertically shows a deviation of no
tighten the foundation bolts evenly and firmly and grout the more than 1.0 mm (0.04 in.). Both pulleys must be parallel.
base plate using low shrinkage concrete.

Shim Shim Shim

≤ 800

align max. 1mm

Fig. 5.3-3 Aligning of V-belt pulleys
Foundation bolts
5.3.2 Place of Installation
Fig. 5.3-1: Fitting required shims (mm)
The volute casing and discharge cover take on
5.3.1 Aligning the Pump / Drive Train approximately the same temperature as the pump fluid.
The discharge cover, bearing assembly and bearing
housing must not be insulated.
Caution All components must be level during
operation unless special provisions for bearing lubrication Take the necessary precautions to avoid burns to
and oil sealing have been made. After attaching the unit to personnel and adjacent equipment.
the foundation and connecting the piping, the pump and
drive train must be thoroughly checked and, if necessary, 5.4 Connecting the Piping
realigned
Caution
Coupling check and realignment must be effected even if Never use the pump itself as an
pump and motor are supplied completely assembled and anchorage point for the piping. The permissible pipeline
aligned on a common base plate. The correct distance forces must not be exceeded (see Section 4.3.5).
between the coupling halves as specified in the installation
plan must be observed. Suction lift lines should be laid with a rising slope towards
the pump and suction head lines with a downward slope
The pump set is correctly aligned if a straight-edge placed towards the pump. The pipelines should be anchored in
axially on both coupling halves is the same distance from close proximity to the pump and should be connected
each shaft at all points around the circumference. In without transmitting any stresses or strains. The nominal
addition, the distance between the two coupling halves diameters of the pipelines should be at least equal to the
must remain the same all around the circumference. Use nominal diameters of the pump nozzles. It is
a feeler gauge, a wedge gauge or a dial micrometer to recommended to install check and shut-off elements in the
verify (see Figures 5.3.2 and 5.3.3). system, depending on the type of plant and pump. It must
be ensured, however, that the pump can still be drained
and dismantled without problems.

10
 LCC
Thermal expansions of the pipelines must be The operating data, the oil level, if required (6.1.1), and
compensated by appropriate measures so as not to the direction of rotation (6.1.4) must be checked. The
impose any extra loads on the pump exceeding the pump set must be primed (6.1.3).
permissible pipeline forces and moments.
• Make sure the unit is properly connected to the
An excessive, impermissible increase in the pipeline electric power supply and is equipped with all
forces may cause leaks on the pump where the medium protection devices.
handled can escape into the atmosphere. • Make sure all auxiliary connections (5.4.1) are
connected and functioning.
Danger of life when toxic or hot media are • If the pump has been out of service for a long period
handled. of time, proceed in accordance with Section 6.4.
6.1.1 Lubricants
The flange covers on the pump suction and discharge Grease Lubricated Bearings
nozzles must be removed prior to installation in the piping. Grease lubricated bearings are packed with grease at the
factory. They should be re-lubricated after the initial 50
5.4.1 Auxiliary Connections hours of operation, and at regular intervals thereafter. See
The dimensions and locations of the auxiliary connections Section 7.2.2.2 for grease lubrication instructions.
(cooling, heating, sealing liquid, flushing liquid, etc.) are
indicated on the installation plan or piping layout. If shaft speeds exceed those in the table below, the
bearing housing temperature should be monitored during
commissioning and additional grease added if it exceeds
Caution These connections are required for proper
o o
100 C (210 F), or if bearings are noisy . In some cases
functioning of the pump and are therefore of vital where external cooling of the housing is poor, it may be
importance! necessary to stop and allow the bearings to cool several
times during this break-in period.
5.4.2 Safety Guards Bearing Shaft Speed (rpm), monitor
Assembly commissioning temperature if over:
In compliance with the accident prevention
35mm 2300
regulations the pump must not be operated without
coupling and drive guards. If the customer specifically 50mm 1800
requests not to include guards in our delivery, then the 70mm 1400
operator must supply them. 100mm 1000
125mm 750
5.5 Final Check
Re-check the alignment as described in Section 5.3. Some lubricant may be expelled from the labyrinth oil
It must be easy to rotate the shaft by hand at the coupling. seals upon startup. This is normal and will stop once the
excess grease has been purged.
5.6 Connection to Power Supply Oil-lubricated bearings
A trained electrician must make the connection to the Units may be shipped without oil from the factory. Fill with
power supply. Check available mains voltage against the the supplied GIW Blue 150 oil to the center of the sight
data on the motor rating plate and select the appropriate gauge.
start-up method. Before starting the pump, verify that the bearing assembly
is correctly filled to the center of the oil level sight gauge.
We strongly recommend the use of a motor protection Do not overfill. Factory filled units contain GIW Blue ISO
device. 150 synthetic bearing oil. This is available as GIW part
number 690-9090-01-B150P. Otherwise, use an
equivalent synthetic or a high quality ISO220 mineral oil
6 Commissioning, Start-up / suitable for use with heavy industrial equipment, anti-
Shutdown friction bearings and oil circulating systems. Such oil
typically have high temperature stability, resistance to
Caution oxidation and foaming, and inhibit rust, corrosion, and the
Compliance with the following formation of deposits. Oils with EP additives are not
requirements is of paramount importance. Damage recommended.
resulting from non-compliance shall not be covered by the o o
For oil temperatures above 85 C (180 F) or for severe
scope of warranty. load conditions, a high quality synthetic lubricant should
be used. Contact your GIW / KSB representative for a
This manual applies to single stage pumps. Procedures recommendation.
for multistage pumps should be obtained from GIW/KSB
sales office. Bearing Assembly Approximate Oil Capacity
liters (quarts)
6.1 Commissioning 35 mm 0.75 ( 0.75 )
Before starting up the pump make sure that the following 50 mm 1.0 ( 1.0 )
requirements are checked and fulfilled. 70 mm 1.75 ( 2.0 )
100 mm 3.0 ( 3.25 )
125 mm 6.0 ( 6.5 )

11
 LCC
For gland flush supply, use suitable non-aggressive clean
Do not overfill the bearing assembly. The capacities listed water not liable to form deposits and not containing
above are approximate. When filling the bearing housing, suspended solids. Hardness should average 5 with a
the oil level must be at the centerline of the oil level sight ph>8. It should be conditioned and neutral with regard to
glass when the shaft is not turning. This is the ”cold level” mechanical corrosion.
and will change as the pump runs and the oil becomes
suspended in the bearings. o o
An Inlet Temperature of 10 to 30 C (50 to 85 F) should
o o
produce a maximum Outlet Temperature 45 C (115 F)
when the gland is properly adjusted.
The constant oil leveler is no longer available. It is not
recommended for use since it can increase oil level
when the pump is running and cause leaks at bearing
seals. Caution Running the pump dry will result in
increased wear on the gland packing and shaft protecting
sleeve or failure of the mechanical seal.
Fill plug
Mechanical Seals
Mechanical seals are precision devices, which require
special care for their proper operation. If pump is equipped
Oil level
sight glass with a mechanical seal, the instruction manual for the seal
should be consulted for special storage, startup and
maintenance requirements.

6.1.3 Priming the Pump and Other Checks

Before start-up, the pump, suction line and (if applicable)
the tank must be vented and primed with the liquid to be
pumped. Any valve in the suction line must be fully open.

Open all auxiliary connections (flushing, sealing, cooling

Oil level with liquid, etc.) and check the through flow.
pump stopped
Drain plug 6.1.4 Checking the Direction of Rotation

Fig. 6.1.1: Oil fill, drain and level Caution

The impeller must rotate in the direction
Underwater Operation indicated by the arrow on the pump casing. This must be
verified by briefly running the motor with the coupling or
Bearing assemblies for use underwater should be
belt drive disconnected. If the motor runs in the wrong
completely filled with oil and slightly pressurized by an oil
direction of rotation, have it corrected and verify direction
recirculation and filtering system. As a result, their
of rotation before reconnecting coupling or belts. If a
capacities will be several times greater than shown above
Variable Frequency Drive (VFD) or other controller is
and a thinner oil will be required. Depending upon the
used, it is recommended to permanently disable
water temperature at the location at which the pumps are
REVERSE and BRAKE function during controller set up.
operating, the ISO viscosity grade should be altered as
follows for mineral oil-based lubricants:
If motive power is applied to the pump, and it is run in the
wrong direction of rotation, even momentarily, the impeller
Water Temperature ISO Viscosity Grade may unscrew causing extensive damage to the entire unit.
o o
0 to 20 C (32 to 70 F) 100 This is especially important during initial start up as the
o o
20 to 30 C (70 to 85 F) 150 impeller may not be fully torqued onto the pump shaft.
o o
over 30 C ( over 85 F) 200
GIW Blue oil may be used for all the above temperatures 6.1.5 Cleaning the Plant Piping

For more information on Underwater Bearing Assemblies The cleaning operation mode and duration for
see section 11.2 and 11.3 flushing and pickling service must be matched to the
casing and seal materials used.

6.1.2 Shaft Seal 6.1.6 Suction Strainer

Packing If a suction strainer has been fitted to protect the pumps
Prior to commissioning, the gland packing supplied with against dirt and/or to retain contamination from the plant;
the pump must be adjusted as described in Section the strainer’s contamination level must be monitored by
7.5.16. Preformed packing rings sets from GIW / KSB are measuring the differential pressure to ensure adequate
recommend. For alternate brands, refer to packing inlet pressure for the pump.
manufacturer’s instructions regarding installation and use
(see Section 2.7).

12
 LCC
6.1.7 Start-up sheet and must be strictly adhered to. If a data sheet is
Before starting the pump ensure that the shut-off element not available, contact your GIW/KSB representative.
in the suction line is fully open. The pump may be started
up against a closed discharge-side swing check valve or
shut-off element. Only after the pump has reached full 6.2.1 Temperature of the Medium Handled, Ambient
rotational speed should the shut-off be opened slowly and Temperature, Bearing Temperature
adjusted to comply with the duty point. When starting up
against an open discharge-side shut-off element, take the Caution
resulting increase in input power into account. Do not operate the pump at temperatures
exceeding those specified on the data sheet or the
nameplate unless the written permission of the
Prolonged operation against a closed shut-off manufacturer has been obtained.
element is not permitted. Danger of steam generation
and explosion! Damage resulting from disregarding this warning will not
be covered by the manufacturer’s warranty.
Caution
Once the operating temperature has been Bearing temperatures, as described in Section 7.2.1, must
reached and / or in the event of leakages, switch off the be observed. Excessive bearing temperature could
unit and re-tighten all bolts. Check the coupling alignment indicate misalignment or other technical problem.
as described in Section 5.3.1 and re-align, if necessary.
6.2.2 Switching Frequency
6.1.8 Shutdown To prevent high temperature increases in the motor and
Under no circumstances should the pipe system be excessive loads on the pump, coupling, motor, seals and
bearings, the switching frequency should not exceed the
equipped with a check valve or other device that can
following number of start-ups per hour (h):
rapidly decelerate the flow rate.
Motor rating max. switchings / hr
Switch off the drive, making sure that the unit runs up to 12kW (16hp) 25
smoothly down to a complete stop. Variable up to 100kW (135hp) 20
Frequency Drive (VFD) and other controllers must more than 100kW (135hp) 10
not use any braking function to slow the pump.
Diesel power trains should disengage the clutch and 6.2.3 Density of the Medium Handled
allow the pump to coast to a stop. The power input of the pump will increase in proportion to
the density of the medium handled. To avoid overloading
Close any auxiliary connections. Pressurized of the motor, pump and coupling, the density of the
bearing lubrication systems must remain running medium must comply with the data specified on the
purchase order.
until all rotation has stopped. If the any part of the
system uses a cooling liquid supply, turn that off only
after the pump has cooled down. Where liquid filled 6.3 Shutdown / Storage / Preservation
shaft seals are used, consult seal maintenance Each GIW / KSB pump leaves the factory carefully
manual for specific shutdown procedures. assembled. If commissioning is to take place some time
after delivery, we recommend that the following measures
In the event of shutdown where a be taken for pump storage.
Caution significant static discharge head exists 6.3.1 Storage of New Pumps
in the system, the impeller can begin to run • Maximum protection for up to 12 months, if the pump
backwards as the flow reverses in the pipeline. This is properly stored indoors.
• Store the pump in a dry location
creates a positive torque on the shaft so the impeller
• Rotate the pump rotor by hand once a month.
connection will not unscrew. Until the flow stops, do
• Follow manufacture’s instructions for mechanical
not close any main line valves. A change in fluid seals.
velocity can create a negative torque on the impeller • See requirements for rubber liner storage below.
and unscrew it from the shaft. This can damage wet
end pump parts as well as bearings, seals and other 6.3.2 Measures to be taken for Prolonged Shutdown
components 1 The pump remains installed; operation check run
In order to make sure that the pump is always ready
Where temperatures may drop below freezing, the for instant start-up and to prevent the formation of
pump and system must be drained or otherwise deposits within the pump and the pump intake area,
protected against freezing. start up the pump set regularly once a month or once
every 3 months for a short time (approx. 5 minutes)
6.2 Operating Limits during prolonged shutdown periods. Prior to an
operation check run ensure that there is sufficient
The pump’s / unit’s application limits regarding liquid available for operating the pump.
pressure, temperature and speed are stated on the data 2 The pump is dismantled and stored

13
 LCC
Before putting the pump into storage carry out all 7.2 Maintenance / Inspection
checks specified in Sections 7.1 to 7.4. It is advisable 7.2.1 Supervision of Operation
to close the nozzles (for ex. with plastic caps or
similar). Caution
The pump should run quietly and free
6.3.3 Storage of Elastomer Linings from vibrations at all times. Unusual noise or vibration
Pumps with elastomer linings should be stored in a cool should be investigated and corrected immediately.
dark location free from electrical equipment such as
motors, or any other ozone generating devices. Exposure Operational procedures that may cause system
to direct sunlight or temperatures in excess of 50°C water hammer must be avoided. Sudden and
(120°F) must be avoided . catastrophic failure of pump casing and plates may
result.
Properly stored elastomer parts will retain their properties
for about two years for gum rubber, or five years for When running the pump against a closed discharge-side
neoprene or urethane. The parts should be periodically shut-off element for a short period, the permissible
inspected for the presence of a soft chalky layer, easily pressure and temperature values must not be exceeded.
rubbed off, which would indicate deterioration. Darkening
or discoloration of elastomer parts over time is a natural Prolonged operation against a closed shut-off
occurrence and does not by itself indicate any loss of element is not permitted. Danger of steam generation
properties. and explosion!

6.4 Returning to Service after Storage The bearing oil temperature may exceed room
o o
Before returning the pump to service carry out all checks temperature by up to 85 C (150 F) but should never rise
o o
and maintenance work specified in Sections 7.1 and 7.2. above +100 C (210 F) except for a brief period during the
breaking in of new bearings. The unit must be shut down
o o
The instructions given in the sections on immediately if temperatures exceed 120 C (250 F).
“Commissioning” (6.1) and “Operating Limits” (6.2) must
be observed. Verify correct oil level as described in Section 6.1.1.

Upon completion of the work, all safety-related and The gland packing (if the pump is fitted with one) should
protective equipment must be properly refitted and/or drip slightly during operation. The gland should only be
reactivated before starting the pump set. gently tightened.

7 Maintenance /Repair Any stand-by pumps installed should be switched on and

7.1 General Instructions off again once a week to keep them operational. Attention
should be paid to the correct functioning of the auxiliary
The LCC pump range is an international product and has
connections.
been designed, in most respects, to the METRIC system
of units using metric components. All fasteners are metric Caution
and will require metric tooling. All seals are metric If the flexible coupling elements begin to
including oil seals, O-rings and stuffing box packing.
show signs of wear, they should be replaced.
Two important exceptions: 1) The suction and discharge
flange bolting patterns are to the American (ANSI)
7.2.2 Lubrication and Lubricant Change
standard, however, flange adapting spools are available.
7.2.2.1 Lubrication
2) The drive end bearing is an inch based taper roller
The rolling element bearings are lubricated with grease or
bearing.
mineral oil. The lubricant change intervals as well as the
required quantity and quality are specified below.
The operator is responsible for ensuring that all
maintenance inspection and installation work is carried out Under severe operating conditions, high ambient
by authorized, duly qualified staff who are thoroughly temperature, high humidity, dust laden air, aggressive
familiar with these operating instructions. industrial atmosphere, etc. the intervals for checking,
replenishing and replacing the lubricant should be
A regular maintenance schedule will help avoid expensive shortened.
repairs and contribute to trouble-free, reliable operation of
the pump with a minimum of maintenance expenditure. 7.2.2.2 Grease Quality / Grease Changes
The bearings are packed with high-quality lithium-soap
Work on the unit must only be carried out with
grease. Under normal operating conditions the fill should
the electrical connections disconnected and locked
be replenished every 1500 hours by an injection roughly
out. Make sure that the pump set cannot be switched
equal to one half of the amount originally used to pack the
on accidentally.
bearings. After 20000 operating hours or 2.5 years the
bearings should be checked, then cleaned and re-
Pumps handling liquids posing health hazards
lubricated if required.
must be decontaminated. When draining the medium
ensure there is no risk to persons or the environment.
For this purpose use high-quality lithium-soap grease, free
All relevant laws must be adhered to.
of resin and acid, not liable to crumble and with good rust-
preventive characteristics. The grease should have a
14
 LCC
penetration number between 2 and 3, corresponding to a shipped separately from the pump and will include
worked penetration between 220 and 295 mm/10. Its drop drawings and bills of material as attachments to this
o
point must not be below 175 C. The bearing cavities basic manual.
should be fully packed with grease.
Dismantling and reassembly must always be carried out in
Bearing Approximate Grease Capacity accordance with the relevant sectional drawing. Any work
Assembly Spherical Taper on the motor, gear reducer, mechanical seal or other non-
Roller Bearing Roller Bearing pump equipment shall be governed by the specifications
35mm 15 ml (1/2 oz) 20 ml (3/4 oz) and regulations of the respective supplier.
50mm 20 ml (3/4 oz) 40 ml (1.5 oz)
70mm 30 ml (1 oz) 90 ml (3 oz) 7.4.2 Dismantling Procedures Impeller
100mm 90 ml (3 oz) 190 ml (6 oz) During normal operation, the impeller becomes tightly
125mm 140 ml (5 oz) 280 ml (10 oz) screwed onto the shaft by the running torque. A steady
torque or mild, yet sudden, torsional jolt is usually required
to disengage the impeller. Several methods of achieving
After adding grease, some excess may be expelled from
this end are possible. One of the easiest methods is
the labyrinth oil seals. This is normal and will stop once
outlined below. To order the jigs described here, contact
the excess grease has been purged.
your GIW / KSB representative. Please provide your
pump assembly number with the order to insure a good fit.
7.2.2.3 Oil Changes
The first oil change should be carried out after 300 Do not apply heat to the impeller hub or nose
operating hours, the following ones after every 3000 hours due to the sealed cavity at the impeller nose.
or when it appears or is suspected of being dirty or DANGER OF EXPLOSION!
contaminated.
Impeller Break-Loose Jig
See section 6.1.1 for oil specifications and capacities. Rotate the impeller until the tip of one blade is facing the
pump discharge. Insert the jig through the eye of the
7.3 Drainage / Disposal
impeller and attach to trailing edge of blade facing
discharge. Rotate the shaft in the direction opposite to
Caution
normal, using the pump pulley or a spanner wrench.
If the pump was used for handling liquids
posing health hazards, see to it that there is no risk to NOTE: For ease of impeller removal, the shaft threads
persons or the environment when draining the medium. should be heavily coated with anti-seize compound during
All relevant laws, local codes, and safety procedures must re-assembly. Also, two aramid paper gaskets should be
be heeded. If required, wear safety clothing and a used between the shaft sleeve and the impeller.
protective mask. BREAK LOOSE JIG

If the media handled by the pumps leaves residues which IMPELLER

might lead to corrosion when coming into contact with
atmospheric humidity, or which might ignite when coming
into contact with oxygen, the unit must be flushed
thoroughly and neutralized.

The flushing liquid used and any liquid residues in the

pump must be properly collected and disposed of without
posing any risk to persons or the environment.

7.4 Dismantling

Before dismantling, secure the pump so as to make

sure it cannot be switched on accidentally. The shut-off
elements in the suction and discharge nozzles must be
closed. The pump must have cooled down to ambient
temperature, it must be drained and its pressure must be Figure 7.4-1 Impeller Break-Loose Jig
released. Observe the safety regulations of Section 7.1.
Impeller Lifting Jig
Repair and maintenance work to the pump must only be For impeller removal or installation, grasp the impeller at
carried out by specially trained personnel, using original the suction eye as shown in Figure 7.4-2. The impeller
equipment spare parts (see 2.7) can be leveled by turning the adjusting bolt which bears
against the impeller nose. This is especially useful during
7.4.1 Sectional Drawings and Bills of Material re-installation. For impeller removal ensure that the lifting
line is tight prior to thread disengagement.
The manual you are reading is a basic manual for all
LCC type pumps. For sectional drawings and bills of
Do not remove, lift, move or re-install impeller without
material relating to your specific pump and
properly using a recommended impeller lifting jig.
equipment, locate an official copy of the
documentation provided by GIW / KSB. This may be

15
 LCC
Removing the Expeller
Before removing the expeller, use two of the holes left
open and two spare bolts, (not included), to secure the
expeller casing (10-7) to the pump pedestal.

If not secured in the above manner, the expeller

casing may fall without warning after the expeller is
removed.

The expeller (23-15) may now be removed from the shaft.

The fit of this part is similar to that of a shaft sleeve (a
close sliding fit). If necessary, the expeller casing may be
unfastened from the pedestal, supported as needed and
used to apply pressure to the expeller in order to force it
from the shaft. This pressure must be applied at several
points around the expeller casing to prevent uneven
loading and potential breakage of the hard iron parts.

Cartridge Bearing Assembly

Drain the oil (if applicable) by removing the drain plug on
the bottom of the housing.

Remove the flingers (if any) and bearing housing end

Figure 7.4-2 Impeller Lifting Jig covers. Care should be taken with the Inpro oil seals,
which should not be removed from the end covers unless
Shell they have been damaged and are in need of replacement.
It is recommended that at least two lift points be used Inspect the seals, gaskets, and o-rings, and discard any
when moving any pump shell. This permits greater safety that appear worn or broken.
and control of the component. Where applicable, GIW The locknut and lock washer that clamp the drive side
pump shells are supplied with cast lifting eyes for this bearing should also be removed. One tab of the lock
purpose. Note that if the chain hook does not fit the lifting washer will be bent into a recess on the lock ring and must
eye, an appropriate clevis should be installed. Another be bent back to allow the lock nut to be unscrewed.
acceptable lifting point is a chain secured around the
discharge flange, being careful not to damage the bolt The shaft and bearings (which are pressed onto the shaft)
flanges. may then be removed as a unit from the drive end of the
housing. Horizontal disassembly is acceptable when
Elastomer-Lined Wet End proper support is given to the shaft to prevent its
Most liners fit snug into the casings. Two threaded push- contacting and marring any of the finished surfaces of the
off holes at 180 degrees are provided in the casings to aid shaft or bearing housing bore. Care should be taken to
in removal. If reuse of the liners is anticipated, care must avoid damaging the grease retaining ring (part 63-7,
be taken to push the liners out evenly to avoid bending of grease lubricated) or spacer ring (part 45-4, oil lubricated)
the steel backing plate. that will come out on the shaft between the two bearings.
Expeller Assembly: The bearings are hot when installed on the shaft, and fit
- for LCC-M Standard Metal Pump tight. It is difficult to remove them from the shaft
After supporting the pump shell, remove the nuts from all undamaged, and they should be removed only if a bearing
four of the studs (902.10) which hold the shell in place and needs to be replaced. Bearings are normally removed by
dismount the shell. heating, which should be done quickly to prevent heating
After supporting the expeller plate (16-4), remove the of the shaft as well. Flame cutting of the outer race and
remaining four through bolts (901.33) and dismount the careful grinding of the inner race may occasionally be
expeller plate. required; however, care must be taken to avoid damaging
the shaft, especially in the oil seal area.
Go to the “removing expeller” section below.
7.5 Reassembly
- for LCC-R and LCC-H Pumps 7.5.1 General Instructions
After supporting the pump shell, remove the nuts from all The pump should be reassembled in accordance with the
eight of the studs (902.10), which hold the shell in place. rules of sound engineering practice. Use the sectional
drawing and bill of material for guidance.
Dismount the shell and the expeller plate (16-4) together,
allowing the expeller plate to rest on and be supported by Before assembly, thoroughly clean all shaft, housing bore,
the eight studs. and end cover surfaces with a suitable solvent to remove
old grease and any water, dust or grit. Clean all
If not removed in the above manner, the expeller dismantled components and check them for signs of wear.
plate may fall without warning after the shell is removed. Damaged or worn components are to be replaced by
original equipment spare parts. Make sure that the seal
faces are clean and the O-rings and gaskets are properly
fitted.
16
 LCC

It is recommended that new seal elements (O-rings/ Caution

gaskets) be used whenever the pump is reassembled. Failure to bend down one of the lock
Make sure that new gaskets have the same thickness as washer tabs may allow the locknut to back-off and lead to
the old ones. Avoid the use of mounting aids as much as premature bearing failure.
possible. Should a mounting aid be required, use a
commercially available contact adhesive. The adhesive
should only be applied at selected points (three to four
spots) and in thin layers. Do not use cyanoacryiate
adhesives (quick-setting adhesives). If in certain cases
mounting aids or anti-adhesives other than those
described are required, please contact the sealing material
manufacturer.

7.5.2 Mounting of Bearings

Caution
The grease retaining ring (63-7, for
grease lubrication) or spacer ring (45-4, for oil lubrication)
must be placed on the shaft between the bearings, and in
the proper orientation, before both bearings are mounted.
Once the bearings are mounted, they cannot be removed
without risk of damage. The grease ring is essential in
protecting the taper bearing from loss of lubrication in the
event of high loadings. Failure to install the ring may
result in significantly reduced bearing life.

The bearings are press fitted to the shaft and should be See Section 7.2.2.2 for grease lubrication requirements
o o
heated to 120 C (250 F) by a suitable bearing heater, oil
bath, or other even heating device prior to mounting. Figure 7.5-1 LCC Drive End Taper Roller Bearing
Flame heating is not recommended. When mounting, it is
important that the bearings are seated fully against the
abutting shaft shoulder. 7.5.3 Inserting Shaft and Bearings into Housing
After insuring the bearing outer diameters and housing
In mounting the taper roller bearing, it is important to heat bores are thoroughly clean, insert the shaft with bearings
the outer race (or cup) along with the inner races (or and grease (or spacer) ring into the housing from the drive
cones) to ensure proper seating against the inner spacer end. It will be necessary to align the grease (or spacer)
required by this preset clearance type bearing. ring as it enters the housing since it has about 6mm (0.25
in.) of clearance with the shaft.
Before the taper roller bearing has cooled on the shaft,
use the lock nut without lock washer to fully seat the Caution
bearing against the shaft shoulder. (The lock washer must The bearings should slide easily and
be left out during this step to prevent damage) fully into the bearing housing without excessive force that
would indicate possible dust or grit between the bearings
After the bearings have cooled, remove the locknut and and the housing, and result in a thrust preloading on the
reinstall with lock washer against the taper roller bearing, impeller end spherical roller bearing. Preloading of the
tightening the nut according to the torque given in Section bearing will cause it to carry thrust loadings, which would
7.5.15. normally be carried by the taper roller bearing and can
result in overheating and premature failure of the spherical
roller bearing.
Caution
Over-tightening can damage the lock 7.5.4 Installing End Covers and Seals
washer and allow the locknut to back off during operation. The standard bearing housing shaft seal is the Inpro VBX
type labyrinth seal. Other seal types may be available
Caution Do not back off the locknut any amount including the Caterpillar Duo-Cone seal for underwater
after tightening in an attempt to set the bearing bearing assemblies. See your arrangement drawing for
clearances. The LCC taper bearing has an internal spacer, specific information regarding these alternate seal types.
which automatically sets the internal bearing clearances.
Prior to installation, press the Inpro shaft seals into each
After tightening, bend down one tab of the lock washer end cover, ensuring that the contaminant expulsion port
into one of the mating grooves on the locknut. If none of and lubrication return trough are located at the 6 o’clock
the tabs are aligned with a groove, locate the nearest one, (bottom) position. If possible, use a hand operated arbor
and further tighten the locknut until the tab can be bent press instead of a hydraulic press to improve control of the
down. pressing operation. You will be overcoming a light
interference fit and may shear off a portion of the outer

17
 LCC
diameter o-ring, however, this is normal and indicates a
secure fit.

Slide end covers with gaskets and Inpro seals over the
shaft at each end, again making certain that the
contaminant expulsion port and lubrication return trough
are located at the bottom. Use a light coating of white
petroleum gel to lubricate the inner diameter o-rings
against the shaft. Take special care when running the
seal over the shaft keyway to avoid cutting the o-ring. If
necessary, lightly file the keyway edges to avoid this
problem.
Figure 7.5-3 Standard LCC Shaft Sleeve Arrangement
After bolting the end covers in place, rotate the shaft by
hand. There should be no frictional contact between the 7.5.6 Mounting Stuffing Box
rotating and stationary parts of the Inpro seal. Any The stuffing box should be mounted so that the sealing
rubbing or axial movement in the seal may indicate water tap is on or near the vertical centerline. This will
misalignment. If this is the case, tap lightly into alignment. position the gland studs at 9 o’clock and 3 o’clock for easy
access. Note that the small stuffing boxes have a single
Note that the drive side end cover clamps against the inlet while the larger sizes have a second port that can be
outer race of the taper roller bearing and may not fit flush used for additional flow or have a pipe plug installed.
against the housing. No shimming is necessary. A gap
of up to 1mm (0.04 in.) is acceptable and within the Location of the stuffing box is provided by a close
tolerance of the parts. Any larger gap may indicate that clearance fit with the pedestal. No additional centering
the taper roller bearing is not fully seated into the housing. operation is required.

For oil lubrication see Section 7.2.2 In some cases, a separate stuffing box wear plate may be
provided. This should be fastened into place with a fresh
gasket.

See Figure 4.3-4 for typical stuffing box arrangement.

7.5.7 Mounting the Bearing Assembly to Pedestal

After mounting the stuffing box (or mechanical seal
adapter) loosely onto the pedestal plate, and screwing the
adjusting screw (909) with nut (924) an appropriate length
into the pedestal, the cartridge bearing assembly may be
placed onto the pedestal saddle. Note that the slotted tab
on the housing must be inserted between the adjusting
screw shoulder and the adjusting nut.

The pedestal and bearing housing saddles should be

clean, dry, and free from oil or grease. If corrosion of the
saddles is a problem, apply a thin film of preservative.
Special care must then be taken in the axial adjustment
procedure to ensure that no movement may occur. (See
the section on Axial Adjustment of Bearing Housing.)
Figure 7.5-2 VBX Inpro Seal for LCC
The four bearing housing hold down clamps (732) may
7.5.5 Mounting Shaft Sleeve now be bolted on, but should remain slightly loose until the
In mounting the shaft sleeve, do not allow anti-seize axial adjustment of the bearing housing is complete.
compound to come in contact with any of the axial faces
of the shaft sleeve, including the impeller contacting face 7.5.8 Metal Expeller Assembly
or the face in contact with the shaft shoulder. For ease of The stuffing box used with an expeller must be of the ‘KE’
removal, a light coating of anti-seize compound should be (low flow) type with a ring of packing between the lantern
applied to the inner diameter of the shaft sleeve. ring and pumped fluid. All rings of packing should be well
coated with water resistant grease during assembly.
Lubrication at any of shaft sleeve or shaft shoulder
faces may result in overloading and breakage of the shaft. Mounting the expeller casing (10-7) to the pedestal using
two spare bolts (not provided) at 180 degrees to each
In many cases, there will be an o-ring which must be other to hold it temporarily in place.
placed on the shaft first, As the shaft sleeve is pushed
into position, this o-ring should be completely forced into Before mounting the expeller (23-15) two 0.5 mm (0.020
the shaft sleeve recess. inch) aramid gaskets (400.31) are placed between the
If a non-split lantern ring or throat busing is being used, it shaft sleeve and the expeller to prevent galling and ensure
should be placed onto the shaft sleeve at this time.
18
 LCC
ease of removal. The gaskets should be installed dry, at both the suction and discharge flanges, although this is
without grease. typically not necessary.

After mounting the expeller, which is a close sliding fit to Some bulging may also occur inside the casing between
the shaft, adjust the bearing assembly towards the drive liners. This is normal and does not affect performance.
end until the expeller just begins to rub on the expeller
casing. Then move it back towards the pump end approx. 7.5.11 Impeller
1.0 mm (0.4 inch). This is a preliminary adjustment. Final Coat the shaft threads heavily with anti-seize compound.
adjustment will be made after wet end assembly is Do not coat the shaft sleeve faces which contact the
complete. impeller and the step in the shaft.

Mount the expeller plate (16-4) at the same time the shell Two 0.5mm (0.020 inch) aramid gaskets (400.10) are
or casing is mounted by inserting the studs into the shell placed between the shaft sleeve and the impeller hub face
or casing and allowing the expeller plate to rest on and be to prevent galling and to ensure ease of impeller removal.
supported by the studs. The gaskets should be installed dry, without grease.

If attempt is made to mount the expeller plate without Screw on the impeller tightly by hand. With larger sizes, it
the support of the shell or casing studs, it will not be may be convenient to hold the impeller stationary while
properly supported and may fall without warning. turning the shaft. Impeller lifting jigs are available to assist
in this operation (see Figure 7.4-2).
See Figure 4.3-5 for typical expeller arrangement. When assembly of the pump is complete, check the
impeller to suction wear plate clearance and adjust if
7.5.9 Mounting Shell necessary, (see section on Axial Adjustment of Bearing
The alignment of the pump shell with the mechanical end Housing).
is obtained through a rabbet fit machined into the
pedestal. For the best wear and efficiency performance, it 7.5.12 Suction Plate and Liner ( LCC-H only)
is essential that the shell be fully seated in this fit. Bolt the suction liner to the suction plate and install o-ring
before mounting to shell.
Ensure that the proper gasket is fitted between the shell
and pedestal before installing. After mounting, the suction liner should protrude
In the case of the elastomer lined LCC-R pump, the liner approximately 1.0 mm (0.4 inch) from the suction plate at
itself forms the seal. See below for additional instructions. the suction flange connection. This is normal and
provides the sealing surface for the suction piping.
7.5.10 Elastomer Lined Wet End
Firmly seat the liners into the metal casings using a large 7.5.13 Axial Adjustment of the Bearing Housing
rubber mallet if necessary. To seat the suction side liner, In order to maximize the performance and reduce wear,
use a wooden brace and large C-clamps, or lay the liner, the clearance between the suction face of the impeller and
flange side up, on a wooden brace and lower the metal the suction liner must be adjusted to a minimum clearance
casing onto it, allowing the weight of the casing to seat the of 0.25 mm (0.010 in.). This is done by moving the
liner. Seat the elastomer flanges into their grooves using bearing housing assembly with the adjusting screw.
a blunt tool if necessary.
Before adjustment may proceed, the pump wet end must
The close fit of the liners, although requiring some effort in be completely assembled. The stuffing box may be
assembly, will ultimately ensure better liner support, and packed before or after the adjustment procedure;
longer wear life. If desired, liquid soap may be used to however, the axial set of any mechanical seal must be left
lubricate the liners during assembly. until after adjustment is complete.

Caution After insuring that the four bearing housing clamps are
Do not use petroleum-based slightly loosened, run the bearing assembly towards the
products to lubricate the liners since they can cause impeller end by means of the adjusting screw until the
degradation of the elastomer. impeller first begins to rub the suction liner. It is helpful to
slowly rotate the impeller during this procedure.
Before assembling the casing halves together, check the
fit of the liners in the casing to ensure that they are seated Next, reverse the adjusting screw until the clearance
correctly, especially in the suction, hub, and discharge between the impeller and the suction liner is a minimum of
flange areas. Clearance allowing for limited readjustment 0.25 mm (0.010 in.).
of parts has been provided in the holes through which the
liner studs protrude. Once the clearance is correct, lightly tighten the bolts of
the four bearing housing clamps by hand, making sure
When bolting the casings together, ensure that the liners that proper contact is maintained at all four locations.
remain well aligned with each other on their outer Next fully tighten the bolts according to the requirements
perimeter, especially in the discharge area. Some bulge of Section 7.5.15. Finally, firmly lock the adjusting screw
may occur at the seam on the discharge flange. This may and nut together against the bearing housing tab.
be removed, and the sealing surface restored to flatness
by lightly buffing with a coarse grade sand paper or Caution
grinding stone. If desired, rubber gaskets may be applied Proper tightening of the bearing housing

19
 LCC
clamps and adjusting nut is essential to prevent movement 7.5.15 Tightening Torques
of the rotating assembly during operation. Failure to do so Taper Bearing Locknut Assembly Torque
can result in severe vibration and damage to all pump
components. Bearing Assembly Locknut Assembly Torque
35 mm 100 N-m (75 ft-lbs)
7.5.14 Expeller Running Clearance 50 mm 135 N-m (100 ft-lbs)
Proper adjustment of the impeller nose clearance as 70 mm 200 N-m (150 ft-lbs)
covered in the section Axial Adjustment of the Bearing 100 mm 375 N-m (275 ft-lbs)
Housing should result in proper expeller clearances in the 125 mm 680 N-m (500 ft-lbs)
new condition and no further adjustments should be
necessary.
Bearing Assembly Clamp Bolts
In some cases, however, adjusting the impeller after
excessive suction liner wear may result in the expeller
rubbing against the expeller plate. In other cases, it is Bearing Bolt size Clamp Bolt Torque
desired to optimize expeller performance rather than Assembly
optimize the impeller clearance. 35 mm M 20 340 N-m (250 ft-lbs)
50 mm
The following procedure is recommended for optimizing 70 mm
expeller performance or for setting the clearances in 100 mm M 24 680 N-m (500 ft-lbs)
pumps containing any worn parts: 125 mm

1 With the suction plate/liner removed, adjust the 1) LCC pumps built prior to 1998 may use clamping bolts
bearing assembly toward the pump end until the back one size smaller than shown above. If your unit is of this
surface of the expeller just begins to rub the expeller plate. type, reduce the torque values as follows:
35,50mm with M16 bolt: 270 N-m (200 ft-lbs)
2 Mount a dial gauge to indicate cartridge bearing 70,100,125mm with M20 bolt: 340 N-m (250 ft-lbs)
assembly axial movement and zero the dial gauge at this
location. Other Bolts
No special torque requirements exist for the remaining
3 Now adjust the bearing assembly toward the drive (or LCC nuts and bolts unless specifically called for on the
motor) end until the expeller vanes just begin to rub on the assembly drawing. Bolts and nuts for which torque is not
expeller casing, or the impeller begins to rub on the hub specified should be tightened enough to ensure a firm
side of the pump shell, whichever comes first. mating between parts in accordance with good
maintenance practice. Where possible, the use of an air
4 Adjust the bearing assembly toward the pump end driven impact wrench is recommended for bolts over
again approximately 1.0 mm (0.04 in.) to provide a 24mm (1.0 inch) diameter.
minimal expeller running clearance. If optimization of
expeller performance is desired, lock the adjustment at For additional torque values see section 9.0
this location.
7.5.16 Mounting the Gland Packing
Caution The stuffing box is equipped with tapped holes for sealing
Optimizing the expeller clearances is water. In order to keep the stuffing box free from abrasive
recommended only in cases where expeller performance particles, the sealing water pressure and gland (452)
is marginal and a small increment in performance is tightness should be adjusted to maintain a small flow of
required to seal against the pump pressure. Setting of cool or lukewarm leakage out of the stuffing box. If the
clearances for optimal expeller performance may result in leakage becomes hot, the gland should be loosened to
excessive impeller clearance and accelerated wear. If allow a greater flow. If cloudiness is seen in the leakage,
necessary, this may be remedied by providing a custom greater water pressure is needed.
fitted machined spacer with gaskets between the impeller
and expeller.
Purge water must be non-aggressive, not liable to form
5 Reassemble the suction plate and check the impeller deposits and not containing suspended solids.
to liner clearance. If not optimizing expeller clearances (Hardness: on average 5; pH > 8, or conditioned and
set the impeller clearance as detailed in the section “Axial neutral with regard to mechanical corrosion).
o o
Adjustment of the Bearing Housing”. Do not allow the dial Inlet temperature tE = 10 to 30 C (50 to 85 F)
o o
gauge to come closer than 1.0 mm (0.04 in.) to the original Outlet temperature tA max. 45 C (115 F)
zero setting or expeller rubbing may occur. If necessary,
consider the use of a spacer as mentioned in step 4. The sealing water pressure required to maintain
satisfactory stuffing box operation will vary with pump
operating pressure, slurry properties, condition of the
packing, and the type of stuffing box. A supply pressure of
10 psi over the discharge pressure of the pump should be
available. In most cases, adjustments to supply pressures
can be made with a manual valve and gauge near the
stuffing box.

20
 LCC
• Gasket Kit • Plate
Caution The stuffing box purge water should be • Expeller
pressure controlled, not flow controlled. The amount of • Gasket Kit
flow from the box should be adjusted to the minimum
amount required to provide cooling. This often results in 7.6.1 Maintenance Procedures for Maximum Parts Life
flow rates considerably less than those given in the table The wear of slurry pump parts is influenced by many
below, which are maximum requirements for worn factors and the following procedures are designed to help
packing. Flow control of stuffing boxes is not you get the most out of your wet end wear parts. If
recommended. It may result in abnormally high sealing problems occur, contact your GIW / KSB representative
pressures and lead to jamming of the packing, excessive for a review of your application.
heat and wear.
Also see section 7.7: “Operational Problems and
Stuffing Box Maximum Seal Water Requirements Solutions”.
Nominal Stuffing Box Type
Suction Liner
Shaft Standard Forward Throat
The suction liner should be rotated 180° at approximately
Size KE Flush Bushing
half-life if localized wear occurs. If localized wear is
35mm 0.09 l/s 0.44 l/s 0.18 l/s severe, repair as recommended by GIW / KSB before
(1.4 gpm) (7 gpm) (2.8 gpm) rotation.
50mm 0.11 l/s 0.54l/s 0.21 l/s
(1.7 gpm) (8.5 gpm) (3.4 gpm) A new gasket should always be used with a new suction
70mm 0.15 l/s 0.76 l/s 0.30 l/s liner or new shell.
(2.4 gpm) (12 gpm) (4.8 gpm)
100mm 0.20 l/s 0.98 l/s 0.39 l/s Impeller
(3.1 gpm) (15.5 gpm) (6.2 gpm) The impeller to suction liner clearance should be adjusted
125mm 0.23 l/s 1.17 l/s 0.47 l/s forward several times during its life cycle for maximum
(3.7 gpm) (18.5 gpm) (7.4 gpm) impeller and suction liner life. See section 7.5.13.

For hot, high pressure or otherwise severe service In general, an impeller does not require replacement until
conditions, an optional combination lantern ring / throat it fails to produce sufficient head for the application.
bushing is recommended in place the standard lantern Impellers are sometimes changed too soon based on
ring and first ring of packing. Water requirements for this appearance. Vibration caused by an impeller wearing out
option will be about mid-way between the forward flush of balance is rare but possible. If this occurs, the impeller
and KE configurations shown in the table above. may be statically balanced by hand grinding on back
shroud.
For expeller applications, the stuffing box used must be of
the ‘KE’ (low flow) type with a ring of packing between the The impeller should never be repaired by welding.
lantern ring and pumped fluid. All rings of packing should
be well coated with water resistant grease during Shell
assembly. If wear is localized with a deep gouge, repair or replace as
recommended by GIW / KSB. Excessive wear
7.6 Spare Parts Stock
Due to the erosive action of the slurry, many of the wet problems are usually indications that the pump is not
end components of the pump may require replacement operating at the flow and head conditions originally
during normal maintenance. Inspection or overhaul of the specified for the design.
mechanical components may also warrant replacement of
certain parts. 7.7 Operational Problems and Solutions
Many pump wear problems are caused by unstable
The following are recommended lists of parts to have on system operation, or off duty pump operation. Although
hand for normal maintenance and inspection. The the dynamics of slurry piping systems cannot be fully
quantities of parts kept in store will depend upon the addressed in this manual, the following items should be
severity of the slurry duty and the number of units considered. Also refer to section 8: “Trouble Shooting”
operating. Maintenance practices may also favor keeping
fully built sub-assemblies or complete pumps on hand in Sump Design
some cases. Previous experience in similar duties often A minimum sump capacity of one minute at the expected
provides the best experience. If in doubt, contact your flow conditions should be provided. Sump design should
GIW / KSB representative for specific recommendations. prevent any uneven flow of the solids to the suction. Often,
a flat bottom sump is best since it will allow the solids to
Wet End Stuffing Box assume a natural slope of repose. The sump should be
• Casing (or casing liners) • Shaft Sleeve observed during operation to insure that solids are not
• Impeller • Seal Water Ring building up and sloughing off.
• Side Liner • Packing
• Gasket Kit • Gasket Kit Sump design should prevent the formation of a vortex, or
other means of introducing air into the pump. Where a
Bearing Assembly Expeller submerged suction is available, the depth of water level
• Bearings • Casing above the pump suction is more important than the cross-

21
 LCC
sectional area of the sump. Frothing of the sump should discharge head against the pump should be increased
be eliminated by the installation of baffles, a submerged (resulting in reduced flow and power consumption).
inlet pipe or other methods to prevent air becoming
entrained in the slurry. If unavoidable, frothing must be If actual supply flow rates are lower than predicted, the
accounted for in the system design and operation. sump may run dry causing the system to surge and
accelerating pump wear. Pump speed or impeller
If the sump runs dry, the system will surge causing diameter should be decreased or make up water
accelerated pump wear. Pump speed or impeller diameter increased to keep the sump at the highest stable level
should be decreased or make up water increased. If the possible. If the flow variations are too great, a variable
flow variations are too great, a variable speed motor may speed motor may be required. This problem is especially
be required. common in applications with a high proportion of static
head, such as mill discharge and cyclone feed. It can be
Cavitation / NPSH Performance further aggravated by operation well below the best
The NPSH available must always be greater than the efficiency flow rate of the pump where the pump head
NPSH required by the pump or cavitation will occur curve is relatively flat. Under these conditions, minor
resulting in head loss (drop in discharge pressure), fluctuations in the system resistance caused by normal
increased wear rate of the pump parts, and shock loading variations in solids concentration or size can result in
of the pump bearing assembly. If any conditions occur, surging flow rates.
consult your GIW / KSB representative for the NPSH
requirements of your pump. Whenever possible, avoid prolonged operation at flows
well below the optimum flow rate. This causes
To maximize the NPSH available to the pump, insure that recirculation of slurry within the pump and encourages
the suction line is as short and straight as possible and the localized wear.
sump level is as high as possible, (or the suction lift as
small as possible in the case of a pump located above the In the event problems are encountered, contact your GIW
water level). Minimizing the number of valves or short / KSB representative. The pump serial number, in addition
radius fittings and attaching a suction inlet bell will also to the following, should be furnished to assist in evaluation
reduce entrance losses. A larger diameter suction pipe of the problem:
may help, but one must be careful not to reduce the flow
velocity below safe carrying levels or bedding of the slurry A. Pump serial number (from the nameplate on the
will occur and result in increased suction liner and impeller pedestal), customer location, and the approximate
wear. startup date.

In dredging applications where a free suction pipe or B. Pumped fluid SG (specific gravity), slurry information
suction cutter head is lowered into the solids to be including SG and particle size, and liquid temperature.
pumped, it is useful to have pressure gauges attached to
the pump suction and discharge. An operator, by C. The approximate flow rate desired, and the actual
observing the gauges, will be able to maintain a maximum minimum and maximum flow rate of the system if
suction vacuum without cavitating the pump. known.

Piping System Design D. The system static head (the difference in elevation
With coarse settling slurries, the pipelines should be between the water level on the suction side of the
vertical or horizontal. Inclined pipelines may surge due to pump and the point of discharge)
a backward drift or build up of solids. Also, an increase in
slurry friction loss may be experienced in these sloped E. The length and size of suction and discharge lines,
lines, further reducing performance. including a description of the general arrangement
including fittings, bends and valves
Piping diameters must be properly sized to maintain
sufficient carrying velocity. Oversized pipelines may result F. If the discharge point is not to atmosphere, what is the
in the formation of a sliding bed of slurry, which can pressure, (e.g. cyclone backpressure).
greatly accelerate the wear of pumps and pipelines.
G. If suction is taken from a sump, provide the general
Operating Conditions of Flow and Head arrangement including size dimensions and minimum
It should be noted that the pump always operates at the and maximum sump levels referenced to the suction
intersection of the pump curve and the pipeline "system" centerline of the pump.
curve.
H. The available driver horsepower, speed of motor and
During the initial stages of operation, motor load on the pump or description of the ratio device between the
pump should be checked. If there is an excess amount of pump and motor.
power being drawn by the pump, it may be caused by the
system head (TDH) being lower than predicted thus I. The impeller diameter if different from that supplied
resulting in higher flow rates and power consumption. This with the pump.
sometimes happens when a safety factor is applied to the
head during the design of the system. Cavitation may also The above items of data are especially important when a
occur under these high flow conditions. The pump speed pump has been transferred from the duty for which it was
should be slowed down to reduce flow, or the total selected to some other application.

22
 LCC
b) High temperature due hot process fluid.
In many instances, it will be found that unusual wear in the c) Leaking caused by excess flush pressure.
pump, or low efficiencies, are caused by a mismatch d) Leaking caused by wrong adjustment.
between the pump and the system application and can be e) Leaking caused by worn parts.
corrected once the operating conditions are known. f) Excess wear of packing or sleeve:
1. Adjusting the packing too tight.
Contact your GIW / KSB representative for further specific 2. Insufficient flush flow or pressure.
recommendations regarding system design. A useful 3. Contaminated flush water.
reference and textbook has also been published by GIW 4. Poor quality packing
titled: “Slurry Transport Using Centrifugal Pumps,” by 5. Failure to lubricate new packing
Wilson, Addie & Clift.
8.5 Overheating of Pump Casing
8 Trouble Shooting See Piping Connection section for details.
a) Hot process fluid being pumped
8.1 Low Flow Rate
b) Prolonged running against shut head or blocked
a) Verify that the pump is correct for the system
discharge.
parameters in terms of flow and head. The pump
NOTE: This is could create a Dangerous condition!!
curve can be used to determine the output, power and
c) Blocked suction
speed.
d) NPSH too low for pump.
b) Depending on the age and service of the pump, parts
e) Air pockets in suction pipe or pump.
could be worn sufficiently to reduce performance.
c) Verify that the motor has the correct power and
voltage required for the system, and is operating 8.6 Pump Leaking
properly. a) Defective gasket at pump flange.
d) Verify that the pump is running at the correct speed. b) Defective seal between pump casing, liner or housing.
e) Verify that the suction side has adequate NPSH (Net c) Casing or liner worn through.
Positive Suction Head) as outlined in the pump d) Normal or excess stuffing box flow
specifications.
f) Check the suction pipe for air pockets, leaks, partially
closed valves or other restrictions. 8.7 Motor Overload
g) Be certain that the suction inlet and impeller are not a) Verify that the motor has the correct power and
clogged. voltage supply, and is operating properly.
h) Verify that the discharge valve is fully open. b) Verify that the motor is correct for the pump. The
pump specifications and curve can be used to
8.2 Bearing Temperature determine the power and speed required
a) During the initial break in period, the bearings will c) Verify that the pumped fluid matches the system
normally run hotter as explained in the Initial Start Up design viscosity and specific gravity.
section. d) Coupling misaligned.
b) Excess temperature may be due hot process fluid e) Gland adjusted too tight.
c) Verify correct oil level. Overfilling causes viscous f) External pipe forces can distort the pump and bind the
drag, which builds heat. motor and pump bearings.
d) Verify oil viscosity. High viscosity and mineral oils g) Drag from external parts such as guards
cause drag and build heat, especially at higher .
speeds.
e) Misalignment of the motor or coupling can create 8.8 Vibrations or Abnormal Noises
excess bearing load and increased heat. a) Cavitation due to low NPSH or blocked suction.
f) Insufficient coupling clearance between the pump b) Impeller rubbing due to incorrect nose adjustment.
shaft and motor shaft can add axial loads to the thrust c) Out of balance impeller.
bearings. d) Debris jammed in impeller vanes.
g) External pipe forces can distort the pump and bind the e) Pump or motor mounting bolts loose
bearings. f) Air in system.
h) Worn or damaged bearings may generate excess g) Large solids in pumped fluid.
heat before failure. h) Coupling misaligned.
i) Drag from external parts such as coupling guards. i) Belts misaligned or incorrectly tightened.
j) Insufficient clearance between the pump shaft and
8.3 Bearing Contamination motor shaft at coupling.
a) Excess leakage at stuffing box k) Worn bearings in pump or motor.
b) Damaged Inpro bearing isolator l) Gland adjusted too tight.
c) Improper maintenance m) Vibrations from system transmitted through piping.
d) Wrong lubricant n) Damaged or bent shaft in pump or motor.
e) End cover seal damaged or missing

8.4 Stuffing Box

See the Packing section for procedures.
a) High temperature due to packing adjusted too tight.

23
 LCC

9 Torque Values for Metric Fasteners

not otherwise Specified

Tightening Torque Values

Class 8.8 Metric Hex Head Capscrews

Metric Coarse & Fine Thread

Thread Dry (reference only) Oil or Thread Lock Anti-Seize

Size in-lbs ft-lbs Ncm Nm in-lbs ft-lbs Ncm Nm in-lbs ft-lbs Ncm Nm
M4 X 0.7 28 316 21 236 17 190
M5 X 0.8 57 644 42 480 34 386
M6 X 1 95 1074 71 800 57 644
M8 X 1.25 228 2576 170 1919 137 1546
M8 X 1 239 2701 178 2012 143 1620
M10 X 1.5 468 38 5288 52 349 28 3940 38 281 23 3173 31
M10 X 1.25 38 52 28 38 23 31
M12 X 1.75 67 91 50 68 40 55
M12 X 1.25 70 95 52 71 42 57
M14 X 2 105 142 78 106 63 85
M14 X 1.5 111 150 83 112 67 90
M16 X 2 158 214 118 160 95 129
M16 X 1.5 166 225 124 168 100 135
M20 X 2.5 317 430 236 320 190 258
M20 X 1.5 339 460 253 342 203 276
M24 X 3 548 743 408 554 329 446
M24 X 2 575 780 428 581 345 468
M30 X 3.5 1098 1489 818 1109 659 893

24
 LCC

NOTES

25
 LCC

10 General Drawing with List of

Components
Pump assembly, bill of material and other drawing or
special instructions relevant to each order will be attached
to the back of this manual.10 Supplements
Supplements provide additional information for optional
equipment.

11 Supplements

Supplements provide additional information for optional

equipment.

11. 1 Stuffing Box Throat Bushing Option

See page 26

11.2 Underwater Pump Operation with Duo-Cone

Bearing Seals
See page 28

11. 3 Duo-Cone Seal

See pages 29-30

26
 LCC
11.1 Stuffing Box Throat Bushing Option

This reference is provided as a supplement to the LCC Technical Booklet. It gives application and part number data
for the LCC Stuffing Box Throat Bushing option.
-----------------------------------------------------------

The standard LCC stuffing box, as seen above, uses one ring of compression packing forward of the lantern ring,
(between the lantern ring and the pumped fluid). This ring of packing serves to reduce the amount of flush water
required by the box.

In some aggressive applications, this forward ring of packing may cause operational problems such as excessive heat
or wear. Although the manner in which the stuffing box is serviced and adjusted will play an important role, the
existence of one or more of the following conditions will increase the chances for problems:

• High operating pressure or temperature.

• Poor seal water quality.
• Chemically aggressive or highly dense and abrasive slurry.

The Throat Bushing option is a one piece ring made of graphite and glass filled Teflon for self lubrication, good heat
transfer and strength. It replaces the standard lantern ring and forward ring of packing. The design incorporates an o-
ring seal on the outer diameter to prevent seal water flow over the top of the ring and a close clearance with the shaft
sleeve to limit seal water usage. Although the throat bushing will not reduce seal water usage to the same level as the
standard forward ring of packing, it will use less than the traditional “forward flush” type of stuffing box.

The apply this option, remove the standard lantern ring and one ring of packing and replace with:
Mechanical End 35 mm 50 mm 70 mm 100 mm 125 mm
Throat Bushing 4240C 4238C 4241C 4239C 4242C
O-ring 7714P-18 7714P-16 7714P-20 7714P-17 7714P-19

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11.2 Underwater Pump Operation with Duo-Cone Bearing Seals

The Underwater Cartridge Bearing Assembly (UCBA) uses Duo-Cone seals in the end cover. Sealing is
accomplished with two hardened, precision ground faces running against each other. An elastomer toric applies
pressure to the faces and allows the seal rings to accommodate axial and radial run out. The contact pressure
and shaft speed will generate heat in the seal faces that must be removed by the surrounding water as the pump
is running. Correct installation and adjustment is extremely critical to the proper function and life of these seals.

Due to the angular position of ladder mounted pumps in most dredge operations, the UCBA must be completely
filled with oil to provide lubrication to the rear thrust bearing when the cutter head is lowered. This requires the
use of tank mounted above the deck to detect leaks and accommodate internal pressure changes. A pressurized
recirculating system can be used, but the simplest method is an expansion tank suitable for operation within the
marine environment. This must be designed to prevent dirt, water or other contaminants from entering the oil
system while providing a vent to atmosphere.

This tank keeps a positive pressure on the bearing side of the Duo-Cone seals to counteract the water pressure
as the pump is submerged. The tank should be mounted high enough to maintain a pressure of about 7 psi (0.5
bar) above what is created by the maximum water depth. Note that the specific gravity of oil is only about 85% of
water and must be taken into account when calculating the mounting height of the tank.

The tank should have an oil level indicator to allow the operator to see if the level changes. After the oil
temperature stabilizes, the level should remain constant and any significant change would indicate a leaking seal.
This early warning can prevent oil from leaking into the surrounding water and avoid bearing failure.

Dredge pumps are designed to run with the UCBA and Duo-Cone seals fully submerged. This enables the
surrounding water to dissipate heat generated by the bearings and seal faces. If the pump will be operated above
the water line for extended periods, the bearings can create extra heat in the oil and the seal faces may overheat.
Provisions should be made to provide a supply of cooling water to each Duo-Cone seal and a water spray onto
the UCBA itself. If the pump will run continuously above water, other sealing systems are recommended, or oil
circulating and seal cooling systems will be required.

Care should be taken to operate the pump within the speed limitations specified by GIW on the pump drawing for
the particular seal size installed. If a seal is replaced, it must be installed with the correct gap (specified by GIW
for each seal size) between the seal holders, as this distance provides the correct seal face pressure for proper
operation.

Failure to operate the seals within the above parameters may result in premature seal failure or oil leakage
through the Duo-Cone seals. Any change in the operating conditions should be discussed with your GIW / KSB
representative to establish if the new conditions are suitable for the equipment.

Isopropyl Alcohol

Lube for Seal Faces

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11.3 Duo-Cone Seals

Rubber Toric

Metal Seal Ring

Seal rings, rubber torics and housings must be

completely clean and free of any oil or dirt. Use a lint
free cloth with a solvent that evaporates quickly and
leaves no residue. It must be compatible with rubber
toric rings. Isopropyl Alcohol or other mild cleaner will
work. Follow all safety guidelines for use according to
the solvent Material Safety Data Sheet. Check the
rubber toric for surface defects and inspect the entire
metal seal face for dirt or marks. Do not place the
polished seal ring face on any surface.

Gently stretch the toric over the metal seal rings until it seats in
the radius. Verify that the toric is not twisted by inspecting the
mold flash line on the outside diameter. Eliminate any irregularity
by gently pulling a section of the toric radially off the ring and
letting it snap back. Twisted torics will cause nonuniform face
load, resulting in leakage and bearing contamination.

Place the housing end cover and seal holder on a flat, clean surface. Verify that the
grooves are clean and free from burrs or sharp edges. Using the correct Seal Installation
Tool, locate the machined ridge in the tool over the toric and clamp together. Align the parts
squarely with the groove and carefully snap the seal assembly into place using a rapid,
even push. Isopropyl alcohol can be used as a lubricant. Allow time for the assembly lube
to evaporate.

Apply a very thin film of pure Molybdenum Disulfide lubricant or light oil to the seal faces
just prior to final assembly. This will lubricate the seals during initial start up. Do not to get
any lube on the rubber toric rings. Be sure there is no debris on either of the seal faces,
since even a small piece of lint can hold the seal faces apart and cause leakage or damage
to the sealing surfaces.

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Final assembly is detailed on the Bearing Housing Assembly drawing. Bolt the
end covers in place and install the two (2) studs and nuts for the installation tool.
Verify that there are no burrs or sharp edges on the shaft that could damage the
o-ring. Coat the long set screws with anti-seize and thread them into the tapped
holes until the points are 1/8” (3mm) from the inside bore. Install the o-ring in the
Seal Holder. Coat the ID of the holder with RTV silicone sealant, including the o-
ring and set screw holes. Place a small bead of silicone around the shaft diameter
to help the o-ring slide. Use extra care at the shaft keyway. Place the gap spacer
over the shaft and carefully slide the holder until it contacts the spacer. Drop the
installation tool over the shaft and tighten the nuts ¼ to ½ turn past Hand Tight
against the tool. The gap spacer should not move and the holder should contact it evenly on all sides. Tighten the
set screws in a crisscross pattern. Remove the installation tool and gap spacer, and then retorque the set screws.
Coat the lock screws with anti-seize and tighten them in the tapped holes. Fill the tapped holes flush to the top
with silicone to protect the set screws. This will make removal easier for future maintenance. Rotate the shaft by
hand and check for smooth operation. Verify that the holders are square to the end cover. The metal seal rings
may appear cocked slightly relative to the holders. This is not a problem, the rings will run true when the pump
starts.

After the assembly is complete, remove one of the pipe plugs from the bearing housing. Install an air line fitting
and slowly pressurize the unit with dry shop air to 10-15 psi or 1 bar. Check all joints and the Duo-Cone seals for
leaks by spraying with a soapy water solution. Do NOT exceed 15 psi, as this could cause the torics to extrude
from the seal grooves. If this occurs, disassemble the unit and reinstall the toric. Release the air pressure, replace
the pipe plug and prepare the unit for shipping or installation on the pump pedestal.

Units being returned to service must be completely filled with oil. Remove the top filler plug and add oil. If the unit
will remain empty during pump installation, be sure it is clearly indicated to ADD OIL prior to start up on both the
pump and the control panel. After the day tank is connected, fill the hoses and tank. Allow time for the oil to
displace the air in the lines. Mark the oil level in the tank for reference. Note that a single hose system or colder
temperatures will require time to bleed all the air from the system. The level should equalize after the pump has
been operating for an hour or two. At this point, fill the tank to the correct operating level.

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