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Visit our website at www.sundyne.com

02.09.02E, 06/03

Effective: June 2003

Supersedes: 10/00

SUNDYNE LMV 322 Pump

Installation & Operation Manual

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DESCRIPTION

WARRANTY

USING THIS MANUAL (ICONS USED)

i INTRODUCTION TO THE SUNDYNE PUMP

ii SAFETY PRECAUTIONS

iii CRITICAL START-UP CHECKLIST

INSTALLATIONINSPECTION

STORAGE

SUCTION AND DISCHARGE PIPING

SEAL ENVIRONMENTAL CONTROL SYSTEM

GEARBOX HEAT EXCHANGER

BASEPLATE AND MOUNTING

DRIVER AND COUPLING

PIPING CONNECTIONS

LUBE SYSTEM

DESCRIPTION

LUBRICATING OIL SYSTEM

OPTIONAL LUBE OIL SYSTEM AUXILIARIESOIL PRESSURE

STARTUP

START-UP PROCEDURES

PUMP CONTROL DURING START-UP

SERVICING

GEARBOX OIL LEVEL

OIL PRESSURE

GEARBOX OILAND FILTER CHANGE

SEAL LEAKAGE

ANTIFRICTION BEARINGSDRIVER

COUPLING

GEARBOX LUBRICANT RECOMMENDATIONS

OPERATION AND CONTROL

FLEXIBLE COUPLING INSTALLATION AND SERVICING

MAINTENANCE

DISASSEMBLY/INSPECTION AND REASSEMBLY OF THE PUMP

DISASSEMBLY/INSPECTION AND REASSEMBLY OF THE GEARBOX

PARTS LIST

GENERAL

RECOMMENDED SPARES

GEARBOX EXCHANGE

REPAIR KITS

ORDERING REPLACEMENT PARTS

CROSS-SECTIONAL ASSEMBLY DRAWING

TROUBLESHOOTING

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TABLE OF CONTENTS

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Sundyne Corporation 2000 All Rights Reserved

DESCRIPTION

ILLUSTRATIONS

FIGURE 1. SEAL PORT IDENTIFICATION

FIGURE 2. SERVICE CHECK POINTS

FIGURE 3. LMV-322 LUBE OIL SCHEMATIC

FIGURE 4. HEAT EXCHANGER MOUNTING

FIGURE 5. LUBE OIL SPECIFICATIONS

TABLES

TABLE 1 FALK COUPLING SPECIFICATIONS

TABLE 2 THOMAS COUPLING SPECIFICATIONS

TABLE 3 PUMP AND GEARBOX TROUBLESHOOTING

TABLE 4 MECHANICAL SEAL TROUBLESHOOTING

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WARRANTY

Sundyne Corporation warrants to Buyer for a period of twelve (12) months from thedate of being placed in service (but not to exceed eighteen (18) months after thedate of shipment) that the equipment at the time of shipment will be free fromdefects of design, material and workmanship. If any defects or malperformance occurduring the warranty period, Sundyne's sole obligation shall be limited to alteration,repair or replacement at Sundyne's expense, F.O.B. Factory, of parts or equipment,which upon return to Sundyne and upon Sundyne's examination prove to bedefective. Equipment and accessories not manufactured by Sundyne are warrantedonly to the extent of and by the original manufacturers' warranty. Sundyne shall notbe liable for damage or wear to equipment caused by abnormal conditions, vibration,failure to properly prime or to operate equipment without flow or caused bycorrosives, abrasives or foreign objects. THE FOREGOING WARRANTY IS EXCLUSIVE

AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIEDINCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANYPARTICULAR PURPOSE. In no event shall Sundyne be liable for consequential orincidental damages.

COPYRIGHT

All rights reserved. No part of this publication may be reproduced, stored in a retrievalsystem or transmitted in any form or by any means, electronic, mechanical,photocopying, recording or otherwise without the prior permission of SundyneCorporation.

1999 Sundyne Corporation

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ICONS USED IN THIS MANUAL

The following icons (symbols) are used to indicate specif

types of information.

It is important to recognize the meaning of these symbol

because danger to personnel or damage to equipment ma

occur, if cautions are not heeded

.

Good ideas to use. A reminder to do something

Equipment use alert. Unless you follow thes

procedures correct ly, the equipment may b

damaged.

Safety alert. Failure to follow these procedure

can endanger the safety of you or o thers.

E lec t r i ca l hazard. Fai lu re to fo l l ow thes

procedures can endanger the safety of you o

others.

USING THIS MANUAL:

This manual is part of the final data package for your

Sundyne LMV centrifugal pump. This manual explains

procedures for the Sundyne pump, including how to:

install it, maintain it, service it, troubleshoot problems

and order parts. In addition to this manual, the final data

package includes: drawings, Sundyne specification

sheet with test performance curves, test data, inspection

data, material certificates if required, driver, coupling and

auxiliary equipment information.Information that may be required regarding

performance, alterations, or detailed technical data

which is not included herein, may be found in the

specification sheet and parts list accompanying the unit,

or may be obtained from your Sundyne representative.

Custom-made auxiliary equipment cannot be shown in

this manual. Refer to the outline drawing for specifics.

Al ways re fe rence th e pump se ri al num ber in any

communication with the factory.

All dimensions are provided in English units followed by

SI units in parenthesis.

Figures and item numbers: parenthetical numbers

included in the text correspond to item numbers on the

illustrated figures. The item number of a part is based

on the part's function, and the correct spare part can be

ordered for any generation pump even if the component

parts do not appear the same as presented in this

revision of the Instruction Manual.

NOTES:

LMV = Line Mounted Vertical Pump

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safety shoes shall be worn. When testing the

equipment, hearing protection is highly recommended

if noise levels exceed 85 dB during an eight (8.0) hour

period. Chemical resistant gloves shall be used if

chemical use is required (see Chemical Use below for

additional information). If chemicals have warnings

regarding fumes and/or dust/mists, a dust mask

respirator shall be worn as a minimum.

When selecting one piece of PPE to be used with

another, consider the compatibility between them. For

example, safety glasses should not interfere with the

seal from hearing protection. Be sure to clean the PPE

after each use.

Use of Forkl i f ts: Al l forkli ft drivers must have a

current recognized license. If using a forklift, first

ensure that the lift is in a safe operating condition.

Electrical Safety: During installation, service, or

repair ensure all electrical sources are off and it is safe

to operate on the equipment. A recognized Lock-

out/Tag-out program should be followed - Locks and/or

tags should be provided warning employees that theequipment is being installed, serviced, and/or repaired.

Once the work is complete, the person installing the

lock and/or Tag shall remove it following your

company's procedure for Lock-out/Tag-out and inform

others of start-up.

Testing Equipment: Persons in the immediate area

shall be warned when a test is to be performed.

Tools: Tools shall be insulated from electrical shock.

Ensure all tools are clean and free of oil and the

insulation is not damaged in any way.

Chemical Use: Any chemicals to be used shall be

accompanied by a relevant material safety data sheet

(MSDS), in accordance with your government

legislation. If applicable, chemical proof gloves shall

be used. An eye wash station (or equivalent) should be

available in the event of injury. Should any hazardous

or flammable chemicals have passed through the

equipment a complete decontamination of the

equipment is required.

Fall Protection: When working over six feet from the

ground, fall protection is required.

Machine Guards: Guards shall remain in place on all

equipment. Only during maintenance/repair can the

guards be removed, and prior to start-up, the guard

must be replaced.

Lock-out/Tag-out Guidelines:Follow Your Company's Lock-Out / Tag-Out

Procedure When Servicing Sundyne Pumps.

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i. INTRODUCTION TO THE SUNDYNE

PUMPThe Sundyne LMV pump has a single stage, with an

integral gearbox. It 's purpose is to increase the

pressure of a continuous flow fluid by applying

centrifugal action. Sundyne LMV Pumps are most

commonly used in HPI, CPI, and Boiler Feed

applications. They are also used in refineries,

petrochemical plants, and power generation plants.

Within these facilities, Sundyne Pumps are used in

high head, low to medium flow processes.

Sundyne LMV Pumps offer industrial quality in a

compact unit that is simple to maintain. It provides

high-energy performance and competitive efficiencies.

For detailed specifications of Sundyne LMV Pumps,

see the specification sheet and bill of material or

consult Sundyne Corp. For the primary components,

reference the Pump and Gearbox section. For more

information about additional custom equipment for the

basic Sundyne LMV Pump product, see the brochure

that accompanies this manual.

ii. SAFETY PRECAUTIONS

Safety Warning

Sundyne Corporation manufactures centrifugal pumps

to exacting International Quality Management System

Standards (ISO 9001) as certified and audited by

Lloyd's Register Quality Assurance Limited. Genuine

parts and accessories have been specifically designed

and tested for use with these products to ensure

continued product quality and performance. As

Sundyne Corp. cannot test all parts and accessories

sourced from other vendors, incorrect design and/orfabrication of such parts and accessories may

adversely affect the performance and safety features

of these products. Failure to properly select, install or

use authorized Sundyne pump parts and accessories

is considered misuse, and damage or failure caused

by misuse is not covered by Sundyne's warranty.

Addi tional ly, modification of Sundyne products or

removal of original components may impair the safety

of these products and their effective operation.

Suggested Safety Instructions:

During installation, maintenance, or repair operations

of a Sundyne pump, systems for safety shall be

applied before the commencement of work. Failure to

take responsibility for safety may lead to injury of

operator or others.

Personal Protective Equipment (PPE): Safety

glasses with side shields, as a minimum, shall be

worn by all personnel install ing or performing

maintenance or repair on the equipment. If equipment

is over 15 pounds (7 kg) and is to be manually lifted, or

if pallet jacks or forklifts are to be used, steel-toed

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iii . CRITICAL STARTUP CHECKLIST

Know Your Machine:

Before servicing and starting up the Sundyne LMV

pump, carefully review the specification sheet, the

outline drawings, performance curves, and this

instruction manual. It is important you become familiar

with the pump configuration before starting and

operating the pump.

Driver Instructions :Carefully follow the installation and starting instructions

provided by the manufacturer of the driver. This is

included in the final data package.

Auxi liaries:

1. Check the utility connections.

2. Verify that the auxiliary piping conforms to

Sundyne's drawings.

3. Verify the connections of the switches, the

instruments, and their settings.

4. Calibrate all measurement equipment (Flow meters,

Current or Ampere meters, Pressure meters, etc.).

Environmental Control System:

Install a system to control the environment of the seal,

if required.

Pressurized Fluid Loop:

Pressurize double seal buffer loop or external seal

flush, if required, prior to admitting fluid into pump

casing.

Check Driver Rotation:

Rotation must be in the opposite direction as the arrow

stamped or cast on the pump casing. Pump rotation iscounterclockwise, while motor rotation is clockwise.

Gearbox Servicing:

Fill gearbox within 1/4 inch (6.4 mm) from top of oil

level sight glass with lube oil which conforms to the

specification in figure 5. Where applicable, operate

auxiliary lube pump to fill heat exchanger and filter.

Add oil as necessary through fill fitting until oil level

stabilizes in sight glass. The gearbox alone requires

approximately four and one-half U.S. quarts (4.25

liters).

Starting Pump:

Start pump with suction valve completely open while

throttling discharge valve, to bring pump to design

operating point.

Heat Exchanger:

If a heat exchanger for the gearbox is installed, adjust

the cooling flow to keep the temperature of the

gearbox sump at 140-160F (60-71C).

Checks:

Check total head, flow rate, and power consumption

against pump specification sheet. Power consumption

should not exceed the maximum shown on the pump

specification sheet. Check that specific gravity

viscosity and NPSH are in accordance with

specification sheet. These conditions will significantly

alter performance of the pump.

Process Conditions:

Do process conditions; suction pressure, suction

temperature, discharge pressure, agree with

specification sheet information? Check with you

Sundyne representative if you must test or run a

different fluid/specific gravity than shown on the

specification sheet.

Auxi liary Lube Pump:

If you have an auxiliary lubrication pump, unlock the

electrical circuit and start it in the "hand" position

Check for oil leaks and recheck the oil level.

Piping Connections:

Are the following bolted/threaded connections tight:

1. Pump flange bolts?

2. Seal environment piping and port connections?3. Cooling water connections to heat exchanger (i

applicable)?

4. Gearbox oil drain plug?

5. Pump case drain plug?


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Inspection

Upon receipt of Sundyne equipment, check for any

damage which may have occurred during shipment.

Notify the carrier and Sundyne promptly if damage has

occurred.

The input shaft may not turn freely due to seal drag

and speed increasing gear meshes; however, if

rotation is "bumpy", this would indicate some disorderor damage and requires investigation for cause.

Storage

If the pump is not to be installed immediately, it should

be protected from exposure to moisture and dust.

Shipping covers installed at the factory (for casing

flanges and seal ports) must be kept securely in place.

Storage instructions provided by the driver (motor or

turbine) manufacturer should be observed.

Long-Term Storage

Certain long-term storage considerations should

be met for any Sundyne pump which will not be

operating for a period of time exceeding six months

from date of factory shipment. This action will ensure

minimum corrosion damage to the gearbox and fluid-

end components. Because of storage location and

other unknown site factors beyond our control,

Sundyne will not accept any liability for damage to the

equipment during the storage period, nor does

Sundyne guarantee the quality of the equipment

during and after the storage period.

To ensure the original quality of the Sundynepump prior to commissioning after storage, all

components must be inspected by an authorized

Sundyne service engineer. Any components not of

Sundyne manufacture (except mechanical seals) must

be inspected by that particular submanufacturer's

authorized service personnel. The cost of such

service personnel and any component replacement

will be at the purchaser's expense.

Factors which affect the quality of an uninstalled

Sundyne pump are the humidity/temperature and the

chemicals in the atmosphere surrounding theequipment. The method employed for long-term

storage should prevent the humidity/temperature and

airborne chemicals from making contact with the

internal components of the equipment.

When the equipment is to be stored in strong chemical

environments or near salt water, protection should be

executed immediately upon receipt of the equipment.

Following are the Sundyne recommended long-term

storage procedures:

1. Indoor, climate controlled building (maintains

constant temperature and humidity).

2. Inert gas purging of component internals.

3. Oil flooding of gearbox internals.

4. Desiccant bags.

Because long-term storage of equipment is of ahighly critical nature, it is recommended that Sundyne

be contacted to provide more details on the above

procedures.

Suction and Discharge Piping

1. The suction line should be clean and a strainer

should be installed to protect the impeller from

damage by mill scale, welding slag, or other foreign

particles during initial startup.

2. All piping must be supported independently of the

pump. The piping should always line up with the pumpflanges. Never draw the piping into place by the use

of force at the f langed suction and discharge

connections as this may impose excessive strains on

the unit.

3. The piping, both suction and discharge, should have

no unnecessary elbows, bends, and fittings, as they

increase friction losses in the piping. The size of pipe

and fittings should be selected carefully and be

sufficient to keep the friction losses as low as practical.

4. The use of elbows near the suction flange should be

avoided. When used, elbows should be long radius.

A straight pipe run of at least ten times the pipe

diameter is desirable between an elbow and the

suction flange.

5. Suction pipe should never be of smaller diameter

than the pump suction inlet.

6. Block valves (both suction and discharge) are

recommended to isolate the pump during shutdown, to

minimize process leakage during the shutdown

condition and to prevent possible reverse rotation due

to back- flow through the pump.

SEAL ENVIRONMENTAL CONTROLSYSTEM

1. For the seals used with the Sundyne LMV pump,

always maintain the environment shown on the

specif ication sheet for your unit. For some

arrangements and applications, you may need a buffer

system to control the seal environment. For many

applications, you can obtain a standard system from

the factory. Make sure that the system is installed

properly and that the ports are open or plugged, as

INSTALLATION

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applicable. Always be sure to leave port 1 free to drain

leakage from the gearbox oil seal and vent the

process seal, otherwise oil could contaminate the

outboard seal or allow process seal leakage into the

gearbox. This port can be attached to a flare line, but

should not have back pressure in excess of 5 psi (34.5

kPa).

2. A liquid buffer system is used with double and

tandem liquid seals. The buffer liquid is introduced into

port 2, allowed to flow through the seal cavity, and out

of port 7.

3. Buffer flow should be 0.5 to 3.0 GPM (1.9 to 11.6

Liters/min) with an inlet temperature of 60 to 120F

(16 to 49C) and inlet pressure as indicated on the

specification sheet.

4.The buffer liquid may require cooling prior to

returning to port 2. Otherwise, heat generated by seal

friction will build up in the buffer, resulting in shorter

seal life.

GEARBOX HEAT EXCHANGER

1. The standard heat exchanger is a shell and tube

water-cooled type.

2. Cool water should be provided at 150 psig (11

kg/cm2) maximum pressure. Coolant flow should be

controlled to maintain a gearbox sump temperature

between 140F to 160F (60C to 71C).

3. The optional air cooled heat exchanger should be

controlled to maintain the same gearbox sump

temperature as above.

NOTE:

Refer to the outline drawing in the LUBE SYSTEM

section for heat exchanger mounting configuration.

The assembly should not be rearranged without

consulting the factory. THE HEAT EXCHANGER

IS NEVER MOUNTED HIGHER THAN THE

GEARBOX MANIFOLD.

A inch socket head pipe plug in the filter

manifold is required when using the gearbox heat

exchanger. (See figure 4.) This plug is omitted

when the heat exchanger is not used.

4. For more detail refer to the appropriate section onLUBE SYSTEM.

BASEPLATE MOUNTING & GROUTING

NOTE: The installation should provide clearance on

either side for removal and service. Overhead

clearance must be provided for lifting out the driver

or gearbox assembly.

1. A rigid concrete mounting base is recommended for

all installations. The concrete foundation should have

minimum deflections and freedom from resonan

frequencies in the operating range of the equipmen

being supported. The flanged base shall be secured in

position by 7/8" diameter bolts. The bolts shall be

installed in the foundation per the Installation Drawing

with sufficient length to protrude 1/4 inch (6.4mm

above the nut.

2. The baseplate, if used should be leveled prior to

grouting. Grout shall set for a minimum of forty eigh

(48) hours before tightening the foundation bolts, o

set for the minimum time suggested by the

manufacturer of the grout.

DRIVER AND COUPLING

1. Drivers are normally shipped separately from the

gearbox and pump. When a splined interconnecting

shaft is supplied, this shaft must be lubricated at each

end with one tube (5cc) of antifretting compound

(Sundyne Part Number MP01AA10). Also available

are solid shaft drivers coupled to the gearbox with a

flexible coupling. See appropriate Section fo

SERVICING the coupling.

2. Spline driven units do not require alignment.

Lock-out starting switch on driver prior to working on

coupling. You should review and know you

company's Lock-out / Tag-out procedure prior to

working on energized equipment.

PIPING CONNECTIONS

Drain lines from the seal housing ports may be

necessary. Refer to the outline drawing for port usage.

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PORT

1

2

5

6

7

DIRECTION

OF DRIVER

ROTATION

DIRECTION

OF IMPELLER

ROTATION

TOP VIEW OF PUMPDESCRIPTION

SEAL DRAIN

SEAL DRAIN SINGLE SEAL

OR BUFFER FLUID IN

(DOUBLE OR TANDEM SEAL)

SEAL FLUSH

SEAL FLUSH

SEAL DRAIN SINGLE SEAL

OR BUFFER FLUID OUT

(DOUBLE OR TANDEM SEAL)

Figure 1. Seal Port Ident ification

PUMPDRAIN

DIRECTION OF DRIVER ROTATION

CAUTION PLATE

REMOVE COVER AND OBSERVE DRIVER SHAFT

ROTATION- MUSTBE SAME AS THATSHOWN BY

ARROW ON PLATE ON TOPOF GEARBOX

HOUSING (DRIVER AND PUMPROTATION INOPPOSITE DIRECTION)

VISUALLYCHECK OILHERE. ALSO

CHECK OILTEMPERATURE HERE

PORTS 2 & 7

CHECK ELECTRICALCONNECTIONS

HERE

LUBE PRESSURE GAGE PORT

FILL-VENTFITTING AND

CAP(ADD GEARBOX OIL

HERE)

EALFLUSH

ORTS 5 & 6

GEARBOX OIL

FILTER

SHAFT

SEALVENT

PORT

SUCTION DISCHARGE

Figure 2. Service Check Points

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between 140F to 160F (60C to 71C)

Approximately one hour may be required to stabilize

temperature. See Figure 4.

The oil filter is a disposable pleated paper elemen

type. Gearbox oil and filter should be changed every

six months. See Figure 5 for oil specifications.

LUBRICATING OIL SYSTEM

INCLUDING REMOTE SKID MOUNTED

SYSTEMS

The oil used in Sundyne gearboxes must meet the

specif ications presented in Gearbox Lubrican

Recommendations (see Bulletin 40.2.04). In general

an ISO viscosity grade 32 oil will meet these

specifications. Before using any oil, you should verify

its properties by consulting its manufacturer. Failure to

use the proper gearbox lubricant will void the warranty

No other additives are recommended.

OPTIONAL LUBE OIL SYSTEM AUXILIARIES

1. Lube Oil Priming Kit

This prelube system is optional on LMV-322 pumps

The kit consists of a motor driven posit ive

displacement pump, check valve, gauges, and

necessary piping. To start pump, operate the prelube

DESCRIPTION

The integral Sundyne lube oil system consists of the

following major components: gearbox sump, main

lube pump, oil heat exchanger and oil filter. Oil is

taken from the sump by the lube pump, then passed

through internal passages to an externally mounted

manifold through the heat exchanger, then through the

filter, and back into the gearbox to the bearings. After

passing through the bearings, the oil drains back to thesump.

The gearbox sump holds approximately four and one-

half U.S. quarts (4.25 liters) of oil, not including

auxiliary piping and heat exchanger. The oil level

should always be maintained within the black circle in

the sight glass. DO NOT overfill gearbox, as this will

cause excessive foaming and overheating.

The main lube pump is a constant displacement gear

type pump directly driven by the input shaft. The lube

pump includes a relief valve plate supported by a

spring under the input shaft.

The standard heat exchanger is a shell and tube water

cooled type mounted on the gearbox manifold. Cold

water should be provided at 150 psig (11 kg/cm2)

maximum pressure. See the specification sheet for

cooling water requirements. Coolant flow should be

controlled to maintain a gearbox sump temperature

Figure 3 LMV-322 Lube Oil Schematic

LUBE SYSTEM

Pressure Gage

Filter

Optional Heat

Exchanger

Internal Lube Pump

Temperature Gage

High Speed Bearing

High Speed BearingLow Speed Bearing

Low Speed Bearing

NOTE: WHEN GEARBOX HEAT EXCHANGER

IS REQUIRED, THE OIL PASSES THROUGH

THE HEAT EXCHANGER BEFORE IT IS

FILTERED.

Sump

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pump at least 30 seconds with a minimum of 5 psig

(0.35 kg/cm2) indication prior to starting the main

driver. (If oil piping has been drained, several minutes,

operation is suggested to allow trapped air to bleed

from the system.)

The prelube pump is to shut down only after main

driver is at full operating speed. Do not operate the

prelube pump continuously when the main pump is

running.

2. REMOTE HEAT EXCHANGER

Some large water cooled and all air cooled heat

exchangers are mounted away from the gearbox.

Except for packaged units, the interconnecting piping

is the purchaser's responsibility. The heat exchanger

MUST be mounted lower than the oi l manifold;

otherwise, air pockets may be present in the lube oil

lines at start-up, causing oil starvation at the bearings.

Equivalent length of piping and fittings must not

exceed 20 feet (6 m), using a minimum of inch (18

mm) I.D. tubing or pipe. If greater pipe lengths are

required, pipe diameter must be increased accordingly.

3. GEARBOX SUMP HEATER

A sump heater is required when ambient temperatures

may fall below the temperature at which the gearbox

oil becomes too viscous for proper lube pump

operation. Both steam and electric sump heaters are

available. The lube oil priming kit MUST be operated

to circulate oil around the heater when the main drive

motor is not running.

OIL PRESSURE

Depending upon the bearing configuration and the

characteristics of the lube oil used. The gearbox

internal lube pump will maintain oil pressure between

45 and 60 psig (3.2 and 4.2 kg/cm2) during normal

operation. The gearbox should never be operated with

less than 10 psig oil pressure.

Figure 4. Heat Exchanger Mounting

A 1/4 INCH SOCKET-HEAD PIPE PLUG IN THE

FILTER MANIFOLD IS REQUIRED WHEN USING

THE GEARBOX HEAT EXCHANGER. THIS PLUG

MUST BE REMOVED WHEN THE HEAT

EXCHANGER IS NOT USED.

THE HEAT EXCHANGER INSTALLATION IS A

SUNDYNE CORP. ASSEMBLY AND SHOULD NOT

BE REARRANGED. THE HEAT EXCHANGER IS

NEVER MOUNTED HIGHER THAN THE FILTER.

GEARBOX MOUNTED

HEAT

EXCHANGER

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c) On units with an auxiliary lubrication pump

operate the pump for a few minutes to remove

trapped air. Vent any high points to assure

complete fill. Add more oil to maintain the

proper level. Adjust the relief valve on the

auxiliary pump to provide 25 psi (1.76

kg/cm2)oil pressure to the system.

d) The auxiliary lubrication system should be

operated for at least 5 seconds before startingthe main pump driver. Pressure switches and

time delays can be used if automatic star

sequences are desired.

e) After the start of the main pump driver, oi

pressure is supplied by the internal gearbox

lube pump. An increase in oil pressure should

be observed.

7. Turn on the cooling water to the lubrication system

heat exchanger. Adjust cooling to maintain oi

temperature in the sump to 140F - 160F (60C

71C).

Start-up sequence

1. Start the auxiliary oil pump, if provided.

2. Pressurize the seal buffer system, if provided.

3. Open the pump suction valve 100%.

4. Open the seal vent port, either #5 or #6 to vent air.

5. Open the pump discharge valve 25%.

6. Start the main pump motor and observe the flow

rate and discharge pressure.

7. Adjust the discharge valve for pump operation

within the recommended flow limits.8. Shut down the auxiliary oil pump within two

minutes of main motor start-up.

Never start or operate the pump against a closed

discharge valve. Always check to ensure tha

the d ischarge va lve i s open to des ign

conditions.

9. On units with heat exchangers, once the gearbox oi

temperature has stabilized, adjust the cooling wate

flow until the oil sump temperature is 140F-160F(60C-71C). Maximum recommended temperature

is 180F (82C ). Recommended sett ing fo

temperature switches are alarm at 180F (82C

and shut down at 200F (93C).

STARTUP

Refer also to the Critical Startup Checklist in

this manual.

If a Sundyne supplied control panel is to be used with

the Sundyne LMV Pump, use the control panel

recommended start-up procedure in addition to the

steps below. Before starting the LMV Pump, complete

the following procedure in the order in which the steps

are provided herein.

Run-In of the Pump: If the pump(s) is to be run-in

under conditions which are considerably different from

those that the unit is designed for (such as type of

liquid, suction pressure, flow rate, etc.) Sundyne

should be consulted to insure that the run-in conditions

are compatible with the pump.

Preparation for unit start-up

1. Make sure that the driver has been serviced as

recommended by the manufacturer.

2. Install a suction strainer to protect the pump fromdebris. After start-up, verify that the strainer is not

clogged, reducing suction pressure. A suction

pressure gage is recommended for this purpose.

Clean the strainer as required.

3. If a buffer fluid, or an external seal flush is required,

this system should be commissioned prior to

admitting process fluid into the pump. This is

required to flush contaminants from the seal

chamber and to lubricate the seals.

4. For double seal configurations, the buffer system

must be pressurized to the pressure specified onthe Sundyne Specification Data Sheet prior to

pressuring the pump with process fluid. Failure to

do so can result in reverse pressurization of the

primary seal, contamination of the buffer system,

and malfunction of the primary seal.

5. Vent the seal cavity through port #5 or #6.

6. Fill the gearbox with clean lubricating oil through the

fill and vent fitting. Use oil conforming to the

specifications in Figure 5. The capacity of the

gearbox is approximately 4.5 quarts (4.25 liters).

a) On units without an auxiliary lubrication pump,

remove the oil filter, fill it 50% full and reinstall.

Remove the heat exchanger, fill it and the

piping 100% and reinstall. Fill the gearbox to

the top of the maximum line on the sight glass.

b) Jog the main drive until oil pressure is

observed on the pressure gauge. This should

occur by the second or third jog of 2-3

seconds duration.

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PUMP CONTROL DURING START-UP

Refer to the Section on "OPERATION AND

CONTROL" for basic instruction. Also refer to the

Sundyne Pump Control Bulletin (01.09.07E) for

additional information on pumps operating in parallel

and series.

SINGLE UNITS

1. Start pump with the suction valve open whilethrottling the discharge valve to bring the pump to the

design flow operating point.

2. If the process fluid is near boiling, a seal cavity vent

back to the supply vessel may have to be opened to fill

the pump with liquid.

PARALLEL OPERATION

1. Check valves must be placed in the discharge

piping of each pump to prevent back-flow.

2. An individual pump minimum flow bypass loop witha control valve should be installed between the pump

discharge and the check valve. The bypass loop

should either be cooled or routed back to the suction

vessel.

3. Start first unit as described above for single units.

4. Start second unit on bypass and maintain flow.

Open discharge valve on second unit and maintain the

design flow of both units. It is preferable that the units

not operate at their peak head capability.

5. Separate f low controls on each pump arerecommended and provide a lower minimum flow

range than can be achieved by pressure control.

NOTE

If an on-line spare pump is started while the main

pump is running, this is considered parallel

operation. This condition could result in the spare

pump dead heading if the bypass loop is not

available. Catastrophic pump failure could result

from operation in a dead headed condition!

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Driver: Inspect the driver to make sure that it performs

according to the manufacturer's specifications.

Coupl ing: Inspect the coupling according to the

manufacturer's specifications.

Never operate the pump without first checking the

coupling guard.

A pump wit h a miss ing or inco rr ec tl y ins ta lled

coupling guard could cause serious or fatal injury.

GENERAL REQUIREMENTS

To increase the operating life of your pump and keep it

in good operating condition, you should inspect and

service it regularly. See figure 2 for check points.

Measure all of the operating parameters documented

in the specific maintenance procedures and log your

measurements. Make sure that all major equipment,

such as lubricating pumps, heat exchangers, and

instrumentation, perform according to themanufacturer's recommendations. Whenever you find

a deviation from specifications, identify its source

immediately, and take any corrective steps that are

required to bring the unit into manufacturer's

specifications.

Regular Maintenance

Gearbox Oil: Check the level of the oil in the gearbox

immediately before and after initial start-up, and

regularly while the pump is running. Be sure to keep

the level of the oil within the design limit. You can add

oil while the pump is running.

DO NOT OVER FILL THE GEARBOX. This can

cause damage to the internal components.

Oil Pressure: The correct oil pressure from the main

pump of the gearbox depends on the configuration of

the bearings and the characteristics of the lubricating

oil used. In the normal operation, the oil pressure

supplied to the gearbox should be between 18-60 psig

(124-413 kPa). Recommended limits are 15 psig (103

kPa) decreasing alarm and 10 psig (69 kPa)

decreasing shutdown.

Changing the Gearbox Oil and Filter: Change the oil

in the reservoir and the oil filter elements every 6

months. Sundyne recommended synthetics may go for

one year maximum before an oil change is required.

Seal Leakage: Check the seal ports regularly.

Excessive leakage is dependent on process liquid, but

considered as approximately one pint per day. If

persistent excessive leakage is present, consider the

use of a double or tandem seal configuration with a

buffer fluid.

Anti -Fri ct ion Bearings: Antifriction ball bearings on

the gearbox low speed shaft should be replaced after

three years, or whenever the unit is being overhauled.

Care must be exercised to ensure that the correct

replacement bearings are installed. Incorrect

replacement bearings will jeopardize mechanical

integrity of the unit. Replacement bearings should be

purchased from Sundyne to ensure proper quality and

fit.

SERVICING

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Figure 5 Recommended gearbox lube oil specifications

The lubricant chosen must be compatible with gearbox elastomers, Viton and Buna N. Any oil that contains an inert

additive such as PTFE, molybdenum disulfide or silicon should not be used in Sundyne gearboxes.

USE OF LUBRICANTS CONTAINING INERT ADDITIVES WILL VOID THE PRODUCT WARRANTY.

Sequence 3 25/0 max.



Foam Limits, ASTM D 892

at 82 C (180F) after 60 minutes Pass

at 54 C (130F) after 30 minutes Pass

Time to 0 emulsion

Demulsibilty, ASTM D 1401

Rust Protection, ASTM 665 A & B Pass

Neutralization Number, Maximum 0.20

Color, ASTM D 1500 1 to 5

Viscosity Index 95 min.

ISO Viscosity Grade 32

Viscosity, Index 95 Minimum

Viscosity cST at 100C 5.2 (44 min. SSU @210 F)

Viscosity cST at 40C 28.8 to 35.2 (150/180SSU @ 100F)

Flash point, C (F) 204 (400) min.

Pour point, C (F) -7 (20 max.)

Gravity, API 28-37

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OPERATION AND CONTROL

OPERATIONRefer to the Sundyne Pump Control Bullet in

(01.09.07E) for addit ion information on pumps

operating in parallel and series.

While the application of the pump in any particular

system is not within the scope of this instruction

manual, the importance of proper operation cannot be

ignored. Several factors must always be considered.

The experienced operator will be aware of the effects.

1.SUCTION CONDITIONS: The most common

reasons for improper centrifugal pump operation are

those relating to proper flow of liquid into the impeller.

To avoid turbulence at the eye of the impeller, the

suction pipe should be straight for a minimum of ten

pipe diameters beyond the suction flange. Another rule

of thumb is that suction piping should be at least one

pipe size larger than the pump suction flange.

It is essential that liquid reaching the impeller eye have

enough vapor pressure to prevent it flashing to a gas

in the impeller. The result of the liquid flashing iscavitation, a phenomenon which can cause damage to

the impeller and inducer. Cavitation is noticeable as a

"pumping gravel" noise in centrifugal pumps. In high

speed single stage pumps this sound may not be

discernible. The way to prevent cavitation is to

maintain suction pressure at a high enough level and

suction temperatures low enough to maintain Net

Positive Suction Head available (NPSHa) greater than

Net Positive Suction Head required (NPSHr) by the

pumps (See Sundyne Specification Sheet).

2. MINIMUM FLOW CONDITIONS: Centrifugal

pumps can also experience vibrations from internal

f low separations and re-circulation at low f low

conditions. The operator should be aware of the

minimum flow recommendations of the manufacturer.

While a pump can operate with some noise due to

recirculation without harm to the pump, excessive

noise and vibration are signs that the pump may be

subject to damage if operation continues. Noise and

vibration may be accentuated by resonance in the

discharge line, especially when a control valve is

located well down stream from the pump.

3. ENTRAINED GASES: Entrained gases in the fluid

will reduce the head and capacity of the centrifuga

pump. Normally it is considered that two to three

percent entrainment is limiting. The pump has beenfound to operate very well under adverse conditions o

gas entrainment. However, the operator should expec

a reduction in performance.

4. SYSTEM HEAD CURVE: The flow at which a

centrifugal pump operates depends upon the point o

intersection of the system (head) curve with the pump

characteristic (head versus flow) curve. In order fo

control to be steady, the system curve must intersec

the pump characteristic curve at a significant angle

Examples of satisfactory and unsatisfactory angles o

intersection are shown on the following diagram.

NOTE: The curve for pump A has a significant angle o

intersection with system curves D and E. The system

curve D could represent a system with the contro

valve wide open while system E could represent the

same system but with the throttle valve partially closed

to reduce flow from flow 1 to flow 2. Pump curve B, on

the other hand, will provide only flow 2, even with the

control valve wide open (curve D). When the contro

valve is partially closed to create system curve E, the

curve E and the lower pump curve B are nearly

parallel. The lack of significant angle of intersection

means that the pump flow is likely to drift aimlessly

and not respond to control valve position.

CONTROL

Proper operation of the Sundyne LMV pump (as with

any other centrifugal pump) requires that the pump be

SYSTEM (HEAD)

CURVES VALVE PARTIALLY CLOSED

VALVE

WIDE

OPENGOOD ANGLE

OF INTERSECTION

AD

B

E

12

HEAD

FLOW

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operated in a range where:

(1) the system head curve and pump performance

curve intersect at a significant angle (2) the pump does

not operate below the minimum flow recommended

and (3) the pump does not operate "in the break" or

beyond the maximum capacity recommended. Rule of

thumb would establish the maximum capacity as 10%

beyond the design flow.

It is recommended that flow control rather than

pressure control always be used with the LMV.Pressure and flow controls both operate by throttling

the discharge flow. However, flow control devices are

much more sensitive to the changes in the point of

intersection of the performance curve with the system

head curve.

Minimum flow is determined by the larger of either:

(1) the amount of flow necessary to prevent damaging

low flow recirculation (2) the amount of flow necessary

to prevent excessive temperature rise in the pump

casing due to low flow recirculation, or (3) in the case

of pumps operated in parallel the minimum flow that

will prevent one from dead-heading the other.

The minimum flow necessary to prevent excessive low

flow recirculation has been found to be largely a

function of the system design. The operation of a

control valve downstream can produce a resonant

condition which can accentuate recirculation vibration

to damaging proportions.

It has been found through experience that the greater

the distance the control valve is located from the pump

discharge flange the more severe the effect of this

vibration.

If the pump is not operated below minimum flow

recommendations, temperature rise within the pump is

unlikely to be a problem. However, if operation at low

flows becomes mandatory, or if the system causes the

pump discharge line to be blocked for any period of

time, a means of maintaining a minimum flow must be

provided. This can be accomplished by use of either a

continuous bypass or by a flow controlled bypass. Any

bypass arrangement must return liquid to the suction

tank or to a location with similar heat sink capacity.

Various devices to protect the pump and system are

available. Devices that monitor vibration, temperature

or pressure changes can be installed. Consult the

manufacturer for recommendations.

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19/53Page 1902.09.02E, 06/03 Visit our website at www.sundyne.com

General Information

(1) If other than Sundyne supplied couplings are used,

they must be flexible disc or gear type couplings

capable of tolerating reasonable amounts of parallel

and angular misalignment, and axial end float. Refer to

coupling manufacturer's recommendations for

installation and maintenance.

Lock out starting switch on driver prior to working

on coupling.

(2) Coupling installation for turbine drivers is identical

to that for motors.

(3) The gearbox coupling hub will normally be

mounted at the factory. The driver coupling hub will be

mounted on all motors and turbines shipped from the

Sundyne factory.

Flexible Disc or Grid Type couplings

(4) If the driver coupling hub is not mounted, the

following procedure should be used:(a) Measure the distance from the top surface of the

gearbox hub to the datum face of the driver adapter

(Figure 6). This will be called the "X" dimension.

(b) From Table 1 or 2, determine the end gap

(distance between coupling hubs) for the size of

coupling provided.

(c) Subtract the end gap values from the "X"

dimension to determine the distance from the driver

datum face to the coupling hub face ("Y" dimension -

Figure 7). Scribe the shaft to show the "Y" dimension.

(d) Make sure the coupling hub bore, keyways, and

shaft are clean, free from burrs, and that the key will fi

in the keyways. Heat the hub in an oil bath or oven to

approximately 250F (121C), or more if necessary, so

the hub will slide onto the motor shaft. Position the

hub at the scribed line on the shaft and tighten the hub

key set screw.

On flexible disk couplings, before the hub is installed

check to see if it is possible to assemble the coupling

bolts and washers (Figure 9) from the motor side othe hub when installed. If this is not possible

assemble the short bolts with bevel washers into the

hub flange before fitting in onto the shaft.

(5) Grid Type Coupling Installation Instructions

(a) The driver adapter has coupling guard plates which

must be removed and stored while installing coupling.

The coupling seals should have a light coating of

grease before installation and assembly. When

mounting or remounting the coupling hub, for any

reason, always put the seal ring on the gearbox ordriver shaft first. Then install the coupling hub. The

coupling will not seal properly if these rings are

omitted (Figure 8).

(b) Mount the driver on the driver adapter and tightenthe attaching bolts.

(c) From Table 1, determine the end gap (distance

between coupling hubs) for the size of coupling

provided.

(d) Using a feeler gauge, check the actual end gap

(Figure 9) to verify that it is within the limits given in

Table 1. If it is not, loosen the hub key set screw and

move the hub up or down until the end gap is within

limits. Retighten the set screw.

FLEXIBLE COUPLING

Figure 6

Figure 7

Figure 8 Grid

Type CouplingDatum Face

Driver

Adaptor

Coupling

Guard

Coupling

Guard

Screw

Datum

Face

Hub Key Screw

Gasket

Lug Up

Vertical

CouplingsSeal

Seal

Grid

Cover

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20/53Page 20 02.09.02E, 06/03Visit our website at www.sundyne.com

Figure 9 Grid Disassembly

Figure 10 Coupling Disassembly

Table 1 Falk Coupling Specifications

(e) It is good practice to coat the coupling assembly

and shafts with grease or some form of protection in

order to minimize the chance of corrosion.

(f) Replace the coupling guards and secure them with

the screws provided.

Servicing the Grid Type Coupling

(a) Couplings should be lubricated at least once ayear. Lubricate more often when the coupling is

exposed to excessive moisture or extreme

temperatures.

Remove both lube plugs and insert one grease fitting.

Fill with grease until excess appears at opposite hole.

Remove fitting and replace plugs.

(b) For operation in ambient temperatures of 0 to

150F (-18 to 66C), grease with the following

specifications should be used:

DROPPING POINT - 300F (149C) or higher.

CONSISTENCY - NLGI #2 with worked penetration

value in the range of 250 to 300.

Falk Coupling Size End Gap Cover Bolt Torque

40T10 0.062 in. (1.57mm) 0.125 in. (3.17mm) 0.188 in. (4.77mm) 100 lb/in (1.15 kg-m)

50T10 0.062 in. (1.57mm) 0.125 in. (3.17mm) 0.188 in. (4.77mm) 200 lb/in (2.30 kg-m)

End

Gap

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SEPARATION AND RESISTANCE - Low oil separation

rate and high resistance to separation from

centrifuging.

LIQUID CONSTITUENT - Good lubricating properties

equivalent to a high quality, well refined, petroleum oil.

INACTIVE - Must not corrode steel or cause swelling

or deterioration of neoprene.

CLEAN - Free from foreign inclusions.

For ambient down to -30F (-34C), a grease with

worked penetration value of 310-340 should be used.

For ambients above or below those given, consult the

Falk Corporation.

(c) If it should be necessary to disassemble the

coupling, the following procedure should be followed.

Remove the cover halves from the coupling. Use a

round rod (for screwdriver) that will fit into the open

loop ends of the grid. Begin at the open end of grid

and pry the grid radially in even, gradual stages,

proceeding alternately from side to side. See Figure

10.

If other than Sundyne supplied couplings are used,

refer to manufacturer's recommendations for

maintenance and lubricating procedures.

Falk Freedom or Thomas Type DBZ Installation

Instructions.

(a) The driver adapter has coupling guard plates tha

must be removed and stored while installing coupling.

The coupling is shipped with the center assembly

assembled as shown in Figure 11 (initial view). If it is

necessary to completely disassemble the cente

assembly, tie a wire through the bolt holes to maintain

the order of the disc packs. Be careful to note the

arrangement of the parts so that the coupling can be

reassembled with the parts in the same order.

Figure 11. Flexible Disk Coupling Alignment

Figure 12

Figure 13. Final Assembly

Thomas Coupling Size End Gap Cover Bolt Torque

Minimum Normal Maximum163 0.876 in. (22.24mm) 0.938 in. (23.81mm) 1.005 in. (25.41mm) 156 lb/in (1.80 kg-m)

201 0.876 in. (22.24mm) 0.938 in. (23.81mm) 1.005 in. (25.41mm) 300 lb/in (3.46 kg-m)

Table 2. Coupling Specifications (Thomas Type DBZ)

End

Gap

Initial View

Note that coupling

is in alignment.

Final View

Bolt

Nut

Washe

Center

Assembly

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22/53Page 22 02.09.02E, 06/03

(b) Mount the driver on the driver adapter and tighten

the attaching bolts.

(c) From Table 2, determine the end gap (distance

between coupling hubs) for the size of coupling

provided.

(d) Using a proper gauge, check the actual end gap

(Figure 12) to verify that it is within the limits given in

Table 2. If it is not, reposition the hub up or down until

the end gap is within limits.

Generally, the gearbox hub is easier to adjust

than the driver hub. If the hub does not move

easily, use a bearing puller and heat the hub.

DO NOT heat hub any more than is absolutely

necessary to loosen it.

(e) Assemble the center assembly to the hubs using

the bolts, nuts, and washers provided keeping the

proper order of parts as noted in step (a). (See Figure

13).

(f) It is good practice to coat the coupling assemblyand shafts with grease or some form of protection in

order to minimize the chance of corrosion.

(g) Replace the coupling guard plates.

(h) Removal for Maintenance - It may not always be

possible to remove or install the center disk pack after

the driver is installed. For easy removal, loosen the

four lower bolts holding the lower disc pack to the

gearbox coupling hub. Remove the mounting bolts

holding the driver adapter to the gearbox. Remove the

driver, the driver adapter and upper coupling as a total

assembly. For assembly, follow this procedure inreverse.

Visit our website at www.sundyne.com

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STEP 1

Remove the driver from the gearbox.

UNITS WITHOUT A FLEXIBLE COUPLING (Shown

here) - Remove attaching bolts. Lift the driver from the

gearbox. Remove the interconnecting shaft (110). Removethe old lubricant from the male and female spline areas of

the interconnecting shaft. Before reassembly, apply 5 cc of

antifrett ing compound (Sundyne Part Number

MP01AA100) to each end of the splined interconnecting

shaft (110).

UNITS WITH A FLEXIBLE COUPLING - (Ref. figure 21)

Remove the coupling housing cover plate (116) by

removing screws (904A). Disengage the input coupling

(117). Remove hex head cap screws (905J). Lift the

driver from the gearbox. Remove the coupling housing

(118) by removing attaching bolts. Remove the coupling

hub (119) from the gearbox low speed shaft (120). Thecoupling hub is installed with a light press fit and may

require a puller to remove it.

The following replacement parts will be required as a result

of pump disassembly and seal housing removal:

PART ITEM NO. QUANTITY

Impeller Tab washer 5 1

O-Ring Repair Kit -- 1

Chemical Barrier Gasket 106 1

(Optional)

The following procedures apply to all configurations of the Sundyne LMV-322 process pump. Refer to the

specification sheet to determine your specific pump configuration and optional equipment included.

Disassembly should be done only to the extent necessary for repair. Parenthetical numbers included in the text

correspond to item numbers in the parts list section.

MAINTENANCE

1. PROCEDURE FOR DISASSEMBLING AND INSPECTING LMV-322 PUMP

Shown here

completely

assembled with

gearbox and driver.

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STEP 2

Remove nuts (914A) from the pump casing studs.

STEP 3

Lift the gearbox and seal housing assembly from the

pump casing. Exercise care not to damage the

inducer (9) if one is installed. Lay the assembly on its

side.

STEP 4

Bend tab washer (5) to allow inducer (9) or impeller nut

to be removed.

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STEP 5

Prevent impeller (2) from turning.

Inducer or impeller bolt assembly will loosen by turning

CW (LEFT-HAND thread)

During reassembly install a new impeller tab washer

(5). Fit tabs into the slot of the inducer or impeller bolt.

STEP 6

Hold impeller (2), remove impeller bolt assembly (3) or

inducer (9), inducer stud (10) and tab washer (5).

STEP 7

Pry impeller (2) from high speed shaft and remove

impeller key (4).Caution:

An induce r or impell er that ha s rubb ed ag ai ns

surrounding surfaces may be out of balance and could

result in high speed shaft bearing failure if re-used in

this condition.

The impeller and inducer are balanced at the factory

to less than 0.01 inch-ounces in two planes.

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STEP 8

Turn gearbox up side down.

Remove two 1/2 pipe nipples from seal housing.

STEP 9

Remove cap screws (905A).

Lift seal housing (30) from gearbox.

STEP 10

Lift out seal rotating face (51A).

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STEP 13

Lift out mechanical seal (60A single) and seal spacer

(52).

Note the position of the chamfer on the seal spacer(against the mechanical seal). Oring (936H) is

positioned against the seal housing.

See figure 17 for cross-sectional drawing and parts list

for single seal arrangement.

O- ring 936H here and on mechanical seal (60A)

Chamfer side (52) toward mechanical seal (60A).

Single Seal arrangement shown here.

Double and Tandem Seal arrangement shown later

STEP 11

Flip seal housing over and remove cap screws (905F),

washers (916B) and throttle bushing (21B).

Remove thermal barrier gasket (87A).

STEP 12

Lift out throttle bushing (21B) and seal retainer space

(19A).

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STEP 14

Flip mechanical seal over carefully inspect the sealing

surfaces for abrasive particles, excessive seal face

wear and binding action of the seal face washer.

Seal repair kits are available for most seals.

Replace or rebuild faulty mechanical seals. A seal may

be rebuilt by replacing the seal face washer, wedge ring

or o-ring, retaining ring, and springs. See specific

information on seals contained in the data package

accompanying the pump.

Replace the seal rotating face (51A) if the wear track isrough or is worn to a depth greater than 0.0002-inch

(0.005mm).

Reassemble as shown in STEPS 12 & 13.

CAUTION:

A combined to tal of 0.010- inch (0 .25mm) may be

removed from the surfaces of the pump rotating seal

face (51A) and gearbox rotating seal face (51D).

Proceed to STEP 20

Reassembly

Insert O ring (936H), seal spacer (52) as shown in

step 13, followed by lower mechanical seal (60A) face

side up, with another O ring (936H) on the face side.

Chamfer side of seal spacer (52) faces the mechanicalseal.

Align parts and install seal retainer spacer (19A).

Double Seal Arrangement STEPS 15 and 16STEP 15 Disassembly

Remove upper mechanical seal (60B), seal rotating face

(51C), (not shown) seal retaining spacer (19A), seal

spacer (52) and lower mechanical seal (60A).

Inspect all parts using step 14 as a guideline.

See figure 18 for double seal arrangement.

STEP 16

Position seal rotating face( 51A)

Align upper mechanical seal (60B).

Proceed to STEP 20.

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STEP 19

Install seal rotating face (51B).

STEP 18

Install seal retaining spacer (19A)

Tandem Seal Arrangement STEPS 17 THRU 19

STEP 17 Disassembly not shown

Remove upper mechanical seal (60B), seal retaining

spacer (19A), seal rotating face (51B), lower mechanical

seal (60A), seal spacer (52) and lower shaft sleeve

(50A).See figure 19 for Tandem Seal arrangement and parts

list.

Reassembly is shown here:

Install lower mechanical seal (50A) rubbing face down.

O-rings (936H) applied to both sides of seal (50A).

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STEP 20 ALL SEALARRANGEMENTS

Install mechanical seal (60B tandem & double) or (60A

single).

Install washers (916B) and cap screws (905F); evenly

tighten and torque per figure 15.

PROCEDURE FOR DISASSEMBLING INSPECTION AND REASSEMBLY OF THE GEARBOX

The following replacement items will be required as a result of gearbox disassembly:

PART ITEM NO. Quantity

5 cc Tube Antifretting Compound --- 2

Gearbox Oil Filter 185 1

Shaft Lip Seal 115 1

Housing Gasket 105 1

O-ring Packing(interconnecting shaft) 936M 2

O-ring Packing(oil seal) 936P 1

O-ring Packing(lower housing oil passage) 936T 1O-ring Packing(slinger sleeve, outer) 936J 1

STEP 21 (after disassembly of pump)

Position gearbox up-side down.

Remove O-ring (936J) and slinger sleeve (50).

Remove high spots from shaft (130) and slinger sleeve

faces (50) so that the seal rotating face will not be

distorted by the clamping force of the inducer stud or

impeller bolt.

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STEP 24

Remove gearbox seal rotating face (51D).

Replace or lap the seal rotating face if the wear track is

rough or is worn to a depth greater than 0.0002-inch

(0.005mm). Lapped surface to be flat within 0.000020-inch (0.0005mm) and parallel to the back surface within

0.0002-inch (0.005mm).

NOTE:

When installing a new or reworked seal rotating face, be

sure that the side with a large chamfer on the inside

diameter is inserted toward the gearbox to clear the

radius on the shaft shoulder.

STEP 22

Remove hex head screws (905L), washers (916K) an

gearbox mechanical seal (60C).

Carefully inspect the mechanical seal and sealing surface

for abrasive particles on the fluid and leakage sides of th

mechanical seal, excessive seal face wear and bindin

action of the seal face washer.

Replace or rebuild faulty mechanical seals. A seal may b

rebuilt by replacing the seal face washer, O-ring, retainin

ring, and springs. See specific information on seal

contained in the data package accompanying the pump

Seal repair kits are available for most seals.

Replace the seal rotating face if the wear track is rough o

is worn to a depth greater than 0.0002-inch (0.005mm).

CAUTION:

A combined total of 0.010-inch (0.25mm) may be remove

from the surfaces of the gearbox rotating faces.

STEP 23

Remove O-ring (936K) from high speed shaft (130).

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STEP 26

From the inside of the input housing (101B), tap out

the old shaft seal (115) with a punch or screwdriver.

Exercise care to avoid damaging the aluminum

gearbox housing or the low speed shaft.

NOTE:

If the housing bore is scratched, apply a light coat of

oil-proof gasket cement to the outside diameter of the

new shaft seal.

STEP 25

Support the gearbox on blocks.

Remove screws (909B), washers (916H) and nuts

(914E).

Separate input gearbox housing (101B) by insertingprybars into the pry slots at the parting flange.

STEP 27Remove the high speed shaft (130) from the output

gearbox housing (101A).

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STEP 29

Remove cap screws(905M) and journal bearing (151A)

from the output gearbox housing (101A).

STEP 28

Remove the input shaft (120) from the output gearbox

housing (101A).

Inspect radial ball bearings (125C and 125D) for smooth

rotation, worn outside diameter of the outer race and

snugness of the inner race on the shaft. Replace if the

bearing has been in operation for more than one year, if

rotation is not smooth, or if the outside or inside

diameter is worn.

Radial ball bearings should be pressed onto the shaft

using a press that contacts only the inner race. Bearingdamage will occur by pressing or pulling on the outer

race. No gap should exist between bearings (125C and

125D), spacers (123A), gear (122A), and shaft

shoulders.

Inspect radial ball bearing contact areas of the input

shaft (120). If the outside diameter of either shaft

bearing surface is less than 1.5748-inches (40.00mm)

install a new shaft.

STEP 30

Drive locating pins (918M) flush with the input gearbox

housing (101B).

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STEP 33Inspect the inside of bearing liners. If the bearing liner

inside diameter is more than 3.5460-inches (90.07mm),

replace the input gearbox housing (101B) or output

gearbox housing (101A), whichever contains the worn

liner. Bearing liners are not replaceable in the field.

STEP 32

Remove and inspect the upper and lower thrust

washers (155B and 155A). If metal is smeared into the

radial lube grooves of the washer face, install a new

washer.

When replacing upper thrust washer (155B) apply

petroleum jelly to the under side to hold the thrust

washer in place when the input gearbox housing is

installed.

STEP 31

Remove cap screws(905N) and journal bearing (151B)

from input gearbox housing (101B).

Inspect the upper and lower journal bearings (151B and

151A). Replace the bearings if the inside diameter of

the upper bearing is more than 0.9418-inch (23.92mm)

or the inside diameter of the lower bearing is more than

1.5020-inches (38.15mm). Refer to Figure 14.

Also , if the bear ings show signs of metal pickup,galling, or overheating they should be replaced.

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LOW SPEED SHAFT AND BEARING LINER CLEARANCES

UPPER JOURNAL BEARING AND HIGH SPEED SHAFT CLEARANCES

LOWER JOURNAL BEARING AND HIGH SPEED SHAFT CLEARANCES

Figure 14 Bearing and Shaft Clearances

TYPICAL CLEARANCES AT BEARING

125C AND 125D AND BEARING LINERS

103C AND 103D

MINIMUM OUTSIDE DIAMETER

OF LOW SPEED SHAFT: 1.5748

INCHES (40.00mm)

RADIAL BALL

BEARING

BEARING LINER

LOW SPEED SHAFT

MAXIMUM INSIDE DIAMETER OF

BEARING LINER: 3.5460 INCHES

(90.07mm)

MAXIMUM INSIDE DIAMETER

OF UPPER JOURNAL BEARING:

0.9418 INCH (23.92mm)

MINIMUM OUTSIDE DIAMETER OF

HIGH SPEED SHAFT AT UPPERJOURNAL BEARING: 0.9368 INCH (23.79mm)

UPPER

JOURNAL BEARING

UPPER

THRUST WASHER

THRUST RUNNER

HIGH SPEED SHAFT

HIGH SPEED SHAFT

LOWER

JOURNAL BEARING

LOWER

THRUST WASHER

MINIMUM OUTSIDE DIAMETER OF

HIGH SPEED SHAFT AT

LOWER JOURNAL BEARING:

1.4960 INCHES (38.00 mm)

MAXIMUM INSIDE DIAMETER OF

LOWER JOURNAL BEARING:

1.5020 INCHES (38.15mm)

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STEP 34

Inspect the high speed shaft thrust runner (133B). If it

shows signs of wear or overheating, it should be

replaced. The thrust runner is shrunk on the shaft;

therefore, use a 10-ton hydraulic press or equivalent for

removal. Inspect the pinion gear before replacing the

thrust runner.Install a new thrust runner by heating it to 375 - 400F.

(191 - 205C) and cooling the shaft to about 0F. (-

18C). The thrust runner should be slipped into place

rapidly to avoid heating the shaft. No more than 0.001-

inch (0.02mm) gap should exist between the shaft

shoulder and the thrust runner.

STEP 36Inspect the high speed shaft at the lower journal

(minimum of 1.4960-inches (38.00mm).

Check for bearing or washer materials on its surfaces. If

there are signs of overheating or wear to a depth

greater than 0.001-inch (0.02mm), install a new gear

and shaft assembly.

STEP 35Inspect the high speed shaft at the thrust runner and

journal bearing contact areas. If the outside diameter of

the shaft is less than 0.9368-inch (23.79mm) at the

upper journal or if the shaft has bearing or washer

materials on its surface, or shows signs of overheating

or wear to a depth greater than 0.001-inch (0.02mm),

install a new gear and shaft assembly.

Inspect the spur gear (122A) and pinion gear (132B) for

pits, chips, gear tooth wear, or excessive wear between

the gear and shaft. The gears are shrunk onto the

shafts. A 10-ton hydraulic press or equivalent is required

for removal. Install a new gear by heating the gear to

375 - 400F. (191 - 205C.), and cooling shaft to about0F (-18C). The gear should be slipped rapidly into

place to avoid heating the shaft. No more than 0.001-

inch (0.02mm) gap should exist between the shaft

shoulder, gear and bearings.

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STEP 37

Check the high speed shaft runout by holding the shaft

in V-blocks on the journal bearing locations and

measure the runout on the keyed end of the shaft using

a dial indicator. The shaft runout must not exceed

0.001-inch (0.02mm).

STEP 38

Remove the lube jets (174C shown and 174D). Clean

all lube passages with solvent and blow-dry with clean

air. Clean all other parts thoroughly and lubricate with

clean turbine oil. Immediately reinstall jets into the

housings.

STEP 39

The lube pump (160) is bi-directional and will provide

lubrication to the bearings regardless of the direction ofrotation.

Installation of the pump requires that the 180 recessed

portion of the lower corner of the bottom stationary plate

be positioned over the roll pin (918N) in the lower

gearbox. In the event that the pump is inadvertently

driven in the wrong direction, the entire lube pump

assembly will rotate 180 and will continue to function to

prevent damage to the bearings.

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STEP 41

The lube pump is driven by the input shaft. A roll pin in theouter rotating part of the pump fits into a slot in the lower

end of the input shaft. The pump relief spring (23A) is

inserted between the pump and input shaft. The correct

engagement of these parts can be checked by pushing

downward on the input gear. The input shaft assembly

should bounce up and down on the relief spring.

STEP 40

Insert the pump relief spring (23A) between the lube

pump and input shaft.

NOTE: Using an O-ring repair kit, replace all O-rings

disturbed by disassembly. Tighten bolts and nuts as

specified in figure 15. Fill the gearbox sump and oil filter

with clean turbine oil as specif ied in "STARTING"

procedures of the "INSTALLATION" section. Check for

freedom of rotation after the pump is completelyassembled.

GearboxItem No. Location Size Torque Value

905H Oil Filter Manifold 3/8 - 16 x 1/2 22 - 25 ft-lbs (30 - 34 N-m)

905L Gearbox Seal 1/4 -20 x 1/2 75 - 80 in-lbs (8.5 - 9.0 N-m)

905M, N Journal Bearings #10 - 24 x 1 35 - 40 in-lbs (4.0 - 4.5 N-m)

905T Chemical Barrier Gasket 1/4 - 20 x 5/8 75 - 80 in-lbs (8.5 - 9.0 N-m)

909B Gearbox Halves 3/8 - 16 x 2 1/2 40 - 45 ft-lbs (54 - 60 N-m)

--- Sight Glass #8 - 32 x 1/2 20 - 22 in-lbs (2.3 - 25. N-m)

Pump

Item No. Location Size Torque Value*3 Impeller Bolt/Inducer 1/2 - 20 36 - 40 ft-lbs (49 - 54 N-m)

905E Mechanical Seal No. Spacer 1/4 - 20 x 12 95 - 102 in-lbs (11 - 12 N-m)

905F Throttle Bushing/Mechanical Seal 1/4 - 20 x 12 95 - 102 in-lbs (11 - 12 N-m)

905G Double Seal with Spacer 1/4 - 20 x 3/4 95 - 102 in-lbs (11 - 12 N-m)

914A Case Nuts 3/4 - 10 250 - 275 ft-lbs (340 - 370 N-m)

914A Case Nuts 7/8 - 9 300 - 330 ft-lbs (410 - 450 N-m)

--- Seal Housing to Gearbox 3/8 - 16 x 1 3/4 35 - 40 ft-lbs (48 - 54 N-m)

905P Separator 1/2 - 20 x 5/8 95 - 102 in-lbs (11 - 12 N-m)

*When using PTFE o-rings, allow 30 minutes between repeated torquing for the PTFE to cold flow.

Figure 15. Torque Values

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STEP 43

Assemble the input housing to the output housing.

Reseat locating pins (918M).

Torque cap screws (909B) and nut (914E) per Figure 15

STEP 42

Install the input shaft (120) then the output shaft (130)

into the output gearbox housing (101A).

Apply a new housing gasket (105) to the parting flange,

and a new O-ring (936T) to the oil port.

STEP 44Install a new shaft seal (115) using a special too

available from the factory. (Tool P/N TO06AA47).

During reassembly lubricate the lip of the new shaft sea

(115) and the outside diameter of the input shaft with

grease or oil.

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STEP 46

Install rotating face (51D), o-ring (936P), gearbox seal

(60C), washers (916K) and hex head screws (905L).

Tighten cap screws evenly and torque per Figure 15.

STEP 45

Lightly tap the new shaft seal into place. If the lip seal

tool is not available, tape the keyway of the shaft prior toinstallation of the lip seal. Use caution to prevent

damage to the seal.

Reassemble the pump to the gearbox in the reverse

order to disassembly.

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GENERAL

Assemblies, subassemblies and components of the

Sundyne LMV-322 Process Pump are illustrated in the

following exploded drawings and cross-sectional

views. Refer to your Sundyne specification sheet for

those options applicable to your pump. The

corresponding parts lists, keyed to each part by item

number, identify detailed parts by part name, quantity

and location.

RECOMMENDED SPARES

Recommended spares are indicated in the quantity

column by an asterisk (*) to the specific quantity. A

double asterisk (**) designates recommended spare

components of a mechanical seal, which may be

stocked other than, or in addition to, the entire

assembled seal. The quantity column and the

indicated spares recommended are based on support

of one pump unit.

The type and quantity of spare parts may vary with

each application, depending upon equipment location,

operating conditions, and the type of liquid being

pumped. An available supply of recommended spares

provides immediate replacement parts without costly

downtime and keeps inventory requirements to a

minimum. You can obtain assistance for planning an

adequate supply of recommended spare parts from

your Sundyne representative.

GEARBOX EXCHANGE

A gearbox exchange can be arranged for a fixed price.

A replacement gearbox, completely tested and with a

full one-year warranty, can be shipped from Sundyne

to anywhere in the Continental United States within 48

hours after receipt of order in Arvada.

REPAIR KITS

Seal and o-ring repair kits are not illustrated herein

but may be purchased directly from the factory. The

use of these kits reduces maintenance time, prevents

assembly mistakes, simplifies stocking and inventory

and reduces delivery time.

ORDERING REPLACEMENT PARTS

When ordering replacement parts, give the pump

serial number and list each part by part number as

shown on the PARTS LIST which is included with each

pump shipment (preferred method), or list each part by

item number (as listed in this manual), part name and

pump model. Specify quantities desired.

Order parts from your local Sundyne representative o

directly from Sundyne Corporation at the address on

the back cover.

PARTS LIST

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(920F) KEY

(120) LOW

SPEED SHAFT

(920A) KEY

(920A)KEY

(160) LUBE

PUMP

(23A) LUBEPUMPSPRING

(125D)

RADIAL BALL

BEARING

(120) LOW

SPEED SHAFT

(122A) SPUR

GEAR

(123A)SHAFT SPACER

(123A) SHAFT

SPACER

(123A) SHAFTSPACER

(125C) RADIAL

BALL

BEARING

(193C) PRESSUREVALVE

(177) VALVE

(98) DUST COVER(FOR USE ON

COUPLED SHAFTONLY)

*(936M) O-RING

PACKING (2)

(115) SHAFTSEAL

(GEARBOX)*

(110) INTERCONNECTINGSHAFT

(186) FILLAND VENT FITTING

(909B) BOLT (6)

(916H) WASHER (12)

(174C) LUBE JET

(101B) GEARBOXHOUSING (INPUT)

(918M) PIN (2)

(905M) HEX HEAD CAP SCREW (2)

(916AA) WASHER (2)

(918N) PIN

(101A) GEARBOX HOUSING (OUTPUT)

(971A) NIPPLE

*(185) OIL FILTER (FRAM PH-16)

(105)HOUSINGGASKET

(916H) WASHER (6)

(914E) NUT (6)

(906B) SOCKET HEAD CAPSCREW (4)

(191) SIGHT GLASS

(193) TEMPERATURE GAGE

(151A) JOURNAL BEARING, LOWER

(51D) SEAL ROTATING FACE

(936P) O-RING PACKING*

(60C) GEARBOX SEAL*

(916K) WASHER (3)

(905L) HEX HEAD CAP SCREW (3)

(174D)

LUBEJET

(924G) PIPE PLUG (2)

(INSTALL ONLY IF OIL

COOLER IS USED)

(936T) O-RINGPACKING*

(916Z)

WASHER

(905N)HEX HEAD

CAP

SCREW

(151B) JOURNAL

BEARING, UPPER

(155B) THRUST

WASHER, UPPER

(133B) THRUST

RUNNER

(132B) PINION GEAR

(920B) KEY (130) HIGH SPEED SHAFT

(155A)

THRUST WASHER,LOWER

(951W)

NIPPLE

(943A)

CAP

(936K) O-RINGPACKING

(87A) HOUSING

GASKET

BA

02.09.02E, 06/03 visit our website at www.sundyne.com

* Recommended Spare Parts

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Sundyne LMV-322

Figure 16 Pump and Gearbox Cross Section

Single Seal Arrangement

Optional

Dual Pressurized

(Double) Seal

Optional

Dual Pressurized

(Tandem) Seal

Optional

Internal Centrifugal

Separator

Optional

Inducer

Note:

1. Item numbers listed above identify only part location

and must be used with parts list for specific pump.

2. A combination of options may be used in a specific unit.

Refer to instruction manual.

3. A solid shaft and flexible coupling is used on some units

instead of splined interconnecting shaft.

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Figure 17 SIngle Seal Arrangement

Item Name Part Name Qty. Item Name Part Name Qty.

19A Seal Retaining Spacer 1 63A - Seal Spring Backup Disc 1**

21B Throttle Bushing 1 64A - Seal Retaining Ring 1**

50 Slinger Sleeve 1* 65A - Seal Spring 6**

51A Seal Rotating Face 1* 68A - Seal Wedge Ring*** 1**

52 Seal Spacer 1 905F Hex Head Cap Screw 3

60A Mechanical Seal (Pump Lower) 1* 916B Washer 3

61A - Retainer & Drive Sleeve Assembly 1 936H O-Ring Packing 3*

62A - Seal Face Washer 1** 936G O-Ring Packing 1*

936H O-Ring Packing 3*

** Recommended Spare Parts 936J O-Ring Packing 2*

** Recommended Seal Space Component Parts 936K O-Ring Packing 1**** Specific to Type 9AB Seal Design

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Figure 18 Double Seal Arrangement


19A Seal Retaining Spacer 1 61B - Retainer & Drive Sleeve Assembly 1

50A Shaft Sleeve (Lower) 1 62B - Seal Face Washer 1**

50B Shaft Sleeve (Upper) 1* 63B - Seal Spring Backup Disc 1**

51C Seal Rotating Face 1* 64B - Seal Retaining Ring 1**

52 Seal Spacer 1 65B -Seal Spring 6**

60A Mechanical Seal (Lower) 1* 68B - Seal Wedge Ring*** 1**

61A - Retainer & Drive Sleeve Assembly 1 905F Hex Head Cap Screw 3

62A - Seal Face Washer 1** 916B Washer 3

63A - Seal Spring Backup Disc 1** 936G O-Ring Packing 1*

64A - Seal Retainer Ring 1** 936H O-Ring Packing 3*

65A - Seal Spring 6** 936J O-Ring Packing 2*

68A - Seal Wedge Ring*** 1** 936K O-Ring Packing 1*

60B Mechanical Seal (Upper) 1*


** Recommended Seal Space Component Parts

*** Specific to Type 9AB Seal Design

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Figure 19 Tandem Seal Arrangement

936G936H

936J

936K


19A Seal Retaining Spacer 1 63A - Seal Spring Backup Disc 1**

50A Shaft Sleeve (Lower) 1 64A - Seal Retainer Ring 1**

50B Shaft Sleeve (Upper) 1* 65A - Seal Spring 6**

51A Seal Rotating Face 1* 68A - Seal Wedge Ring*** 1**

51B Seal Rotating Face 1* 60B Mechanical Seal (Upper Alternate Gas) 1*

51C Seal Rotating Face 1* 61B - Seal Retainer 1**

52 Seal Spacer 1 62B - Seal Face Washer 1**

60A Mechanical Seal (Lower) 1* 65B - Garter Spring 1**

61A - Retainer & Drive Sleeve 1 68B - Backing Ring 2**

62A - Seal Face Washer 1** 69B - O-Ring Packing or Tec Seal 1**

63A - Seal Spring Backup Disc 1** 905F Hex Head Cap Screw 364A - Seal Retainer Ring 1** 916B Washer 3

65A - Seal Spring 6** 936G O-Ring Packing 1*

68A - Seal Wedge Ring*** 1** 936H O-Ring Packing 3*

60B Mechanical Seal (Upper) 1* 936J O-Ring Packing (2 pc. seal requires 3) 2*

61B - Retainer & Drive Sleeve Assembly 1** 936K O-Ring Packing 1*

62B - Seal Face Washer 1**


** Recommended Seal Space Component Parts

*** Specific to Type 9AB Seal Design

ALTERNATE GAS SEAL (UPPER 60B)

ALTERNATE TWO PIECE UPPER SEAL

ROTATING FACE (REPLACING 51B)

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Figure 20 Inducer and Inducer Stud

Figure 21 Flexible Coupling Adapter

Item Name Part Name Qty.

9 Inducer 1

10 Inducer Stud 1


116 Coupling Housing Cover 1

117 Input Coupling 1

118 Coupling Housing 1

119 Hub 1

904A Screw 4

905J Hex head Cap Screw 4

909D Bolt 4

914D Nut 4914H Nut 4

916E Washer 4

916M Washer 4

916R Washer 4

916Y Washer 4

920E Key 1

101A (REF)

2 (REF)

10

9

5 (REF)

30 (REF)

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Figure 22 Chemical Barrier Gasket

Figure 23 Discharge Orifice

93 Discharge Piping


106 Chemical Barrier Gasket 1*

107 Seal Spacer 1

905T Hex Head Cap Screw 3

916V Seal Washer 3*

* Recommended Spares


93 Discharge Orifice 1

916V 905T107 106

101A (REF)

130 (REF)

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LMV-322-IOM_0603

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