Documente Academic
Documente Profesional
Documente Cultură
02.09.02E, 06/03
Effective: June 2003
Supersedes: 10/00
TABLE OF CONTENTS
DESCRIPTION
PAGE
WARRANTY
USING THIS MANUAL (ICONS USED)
i INTRODUCTION TO THE SUNDYNE PUMP
ii SAFETY PRECAUTIONS
iii CRITICAL START-UP CHECKLIST
INSTALLATION
INSPECTION
STORAGE
SUCTION AND DISCHARGE PIPING
SEAL ENVIRONMENTAL CONTROL SYSTEM
GEARBOX HEAT EXCHANGER
BASEPLATE AND MOUNTING
DRIVER AND COUPLING
PIPING CONNECTIONS
4
5
6
6
7
8
8
8
8
8
9
9
9
9
LUBE SYSTEM
DESCRIPTION
LUBRICATING OIL SYSTEM
OPTIONAL LUBE OIL SYSTEM AUXILIARIES
OIL PRESSURE
10
10
10
10
11
STARTUP
START-UP PROCEDURES
13
13
14
SERVICING
GEARBOX OIL LEVEL
OIL PRESSURE
GEARBOX OIL AND FILTER CHANGE
SEAL LEAKAGE
ANTIFRICTION BEARINGS
DRIVER
COUPLING
GEARBOX LUBRICANT RECOMMENDATIONS
15
15
15
15
15
15
15
15
16
17
19
MAINTENANCE
DISASSEMBLY/INSPECTION AND REASSEMBLY OF THE PUMP
DISASSEMBLY/INSPECTION AND REASSEMBLY OF THE GEARBOX
23
23
30
PARTS LIST
GENERAL
RECOMMENDED SPARES
GEARBOX EXCHANGE
REPAIR KITS
ORDERING REPLACEMENT PARTS
41
41
41
41
41
41
42
TROUBLESHOOTING
50
Page 2
02.09.02E, 06/03
DESCRIPTION
PAGE
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
10
10
11
12
16
TABLES
TABLE 1 FALK COUPLING SPECIFICATIONS
TABLE 2 THOMAS COUPLING SPECIFICATIONS
TABLE 3 PUMP AND GEARBOX TROUBLESHOOTING
TABLE 4 MECHANICAL SEAL TROUBLESHOOTING
20
21
50
52
Page 3
COPYRIGHT
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system or transmitted in any form or by any means, electronic, mechanical,
photocopying, recording or otherwise without the prior permission of Sundyne
Corporation.
1999 Sundyne Corporation
WARRANTY
Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the
date of being placed in service (but not to exceed eighteen (18) months after the
date of shipment) that the equipment at the time of shipment will be free from
defects of design, material and workmanship. If any defects or malperformance occur
during the warranty period, Sundyne's sole obligation shall be limited to alteration,
repair or replacement at Sundyne's expense, F.O.B. Factory, of parts or equipment,
which upon return to Sundyne and upon Sundyne's examination prove to be
defective. Equipment and accessories not manufactured by Sundyne are warranted
only to the extent of and by the original manufacturers' warranty. Sundyne shall not
be liable for damage or wear to equipment caused by abnormal conditions, vibration,
failure to properly prime or to operate equipment without flow or caused by
corrosives, abrasives or foreign objects. THE FOREGOING WARRANTY IS EXCLUSIVE
AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED
INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE. In no event shall Sundyne be liable for consequential or
incidental damages.
Page 4
02.09.02E, 06/03
NOTES:
LMV = Line Mounted Vertical Pump
02.09.02E, 06/03
Page 5
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/or
fabrication 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.
Additionally, modification of Sundyne products or
removal of original components may impair the safety
of these products and their effective operation.
Lock-out/Tag-out Guidelines:
Follow Your Company's Lock-Out / Tag-Out
Procedure When Servicing Sundyne Pumps.
02.09.02E, 06/03
Page 7
INSTALLATION
Inspection
Storage
Long-Term Storage
SEAL ENVIRONMENTAL
SYSTEM
CONTROL
02.09.02E, 06/03
PIPING CONNECTIONS
Drain lines from the seal housing ports may be
necessary. Refer to the outline drawing for port usage.
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 on
LUBE SYSTEM.
Page 9
PORT
1
2
5
6
7
DESCRIPTION
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)
SUCTION
DIRECTION
OF DRIVER
ROTATION
DISCHARGE
DIRECTION
OF IMPELLER
ROTATION
SHAFT
SEAL VENT
PORT
PORTS 2 & 7
PUMP DRAIN
GEARBOX OIL
FILTER
Figure 2. Service Check Points
Page 10
02.09.02E, 06/03
LUBE SYSTEM
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 the
sump.
The gearbox sump holds approximately four and onehalf 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
REMOTE
SKID
MOUNTED
Pressure Gage
Filter
Optional Heat
Exchanger
Sump
Temperature Gage
Page 11
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.
GEARBOX MOUNTED
HEAT
EXCHANGER
02.09.02E, 06/03
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 from
debris. 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 on
the 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.
02.09.02E, 06/03
Page 13
Page 14
02.09.02E, 06/03
SERVICING
Driver: Inspect the driver to make sure that it performs
according to the manufacturer's specifications.
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 the
manufacturer'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-Friction 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.
02.09.02E, 06/03
Page 15
Gravity, API
28-37
-7 (20 max.)
204 (400) min.
1 to 5
0.20
Pass
Pass
Pass
25/0 max.
50/0 max.
25/0 max.
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.
Page 16
02.09.02E, 06/03
SYSTEM (HEAD)
CURVES
CONTROL
Proper operation of the Sundyne LMV pump (as with
any other centrifugal pump) requires that the pump be
HEAD
D
GOOD ANGLE
OF INTERSECTION
FLOW
02.09.02E, 06/03
VALVE
WIDE
OPEN
Page 17
Page 18
02.09.02E, 06/03
FLEXIBLE COUPLING
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.
shaft are clean, free from burrs, and that the key will fit
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 of
the 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.
Datum Face
Figure 8 Grid
Type Coupling
Lug Up
Gasket
Cover
Driver
Adaptor
Vertical
Couplings
Seal
Grid
Seal
Datum
Face
Page 19
End
Gap
End Gap
0.125 in. (3.17mm)
0.125 in. (3.17mm)
Page 20
02.09.02E, 06/03
Figure 12
End
Gap
Minimum
0.876 in. (22.24mm)
0.876 in. (22.24mm)
End Gap
Normal
0.938 in. (23.81mm)
0.938 in. (23.81mm)
Initial View
Bolt
Nut
Washers
Center
Assembly
02.09.02E, 06/03
Page 21
Page 22
02.09.02E, 06/03
MAINTENANCE
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.
1. PROCEDURE FOR DISASSEMBLING AND INSPECTING LMV-322 PUMP
The following replacement parts will be required as a result
of pump disassembly and seal housing removal:
PART
Shown here
completely
assembled with
gearbox and driver.
ITEM NO.
5
-106
QUANTITY
1
1
1
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). Remove
the old lubricant from the male and female spline areas of
the interconnecting shaft. Before reassembly, apply 5 cc of
antifretting 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). The
coupling hub is installed with a light press fit and may
require a puller to remove it.
02.09.02E, 06/03
Page 23
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.
Page 24
02.09.02E, 06/03
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 inducer or impeller that has rubbed against
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.
02.09.02E, 06/03
Page 25
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).
Page 26
02.09.02E, 06/03
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 spacer
(19A).
02.09.02E, 06/03
Page 27
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 is
rough or is worn to a depth greater than 0.0002-inch
(0.005mm).
Reassemble as shown in STEPS 12 & 13.
CAUTION:
A combined total 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 mechanical
seal.
Align parts and install seal retainer spacer (19A).
STEP 16
Position seal rotating face( 51A)
Align upper mechanical seal (60B).
Proceed to STEP 20.
Page 28
02.09.02E, 06/03
STEP 18
Install seal retaining spacer (19A)
STEP 19
Install seal rotating face (51B).
02.09.02E, 06/03
Page 29
ITEM NO.
--185
115
105
936M
936P
936T
936J
Quantity
2
1
1
1
2
1
1
1
Page 30
02.09.02E, 06/03
STEP 22
Remove hex head screws (905L), washers (916K) and
gearbox mechanical seal (60C).
Carefully inspect the mechanical seal and sealing surfaces
for abrasive particles on the fluid and leakage sides of the
mechanical seal, excessive seal face wear and binding
action of the seal face washer.
Replace or rebuild faulty mechanical seals. A seal may be
rebuilt by replacing the seal face washer, O-ring, retaining
ring, and springs. See specific information on seals
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 or
is worn to a depth greater than 0.0002-inch (0.005mm).
CAUTION:
A combined total of 0.010-inch (0.25mm) may be removed
from the surfaces of the gearbox rotating faces.
STEP 23
Remove O-ring (936K) from high speed shaft (130).
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 0.000020inch (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.
02.09.02E, 06/03
Page 31
STEP 25
Support the gearbox on blocks.
Remove screws (909B), washers (916H) and nuts
(914E).
Separate input gearbox housing (101B) by inserting
prybars into the pry slots at the parting flange.
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 27
Remove the high speed shaft (130) from the output
gearbox housing (101A).
Page 32
02.09.02E, 06/03
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. Bearing
damage 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 29
Remove cap screws(905M) and journal bearing (151A)
from the output gearbox housing (101A).
STEP 30
Drive locating pins (918M) flush with the input gearbox
housing (101B).
02.09.02E, 06/03
Page 33
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 bearings show signs of metal pickup,
galling, or overheating they should be replaced.
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 33
Inspect 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.
Page 34
02.09.02E, 06/03
BEARING LINER
RADIAL BALL
BEARING
LOW SPEED SHAFT
MAXIMUM INSIDE DIAMETER OF
BEARING LINER: 3.5460 INCHES
(90.07mm)
THRUST RUNNER
LOWER
THRUST WASHER
LOWER
JOURNAL BEARING
Page 35
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 0.001inch (0.02mm) gap should exist between the shaft
shoulder and the thrust runner.
STEP 35
Inspect 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 about
0F (-18C). The gear should be slipped rapidly into
place to avoid heating the shaft. No more than 0.001inch (0.02mm) gap should exist between the shaft
shoulder, gear and bearings.
STEP 36
Inspect 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.
Page 36
02.09.02E, 06/03
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 of
rotation.
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.
02.09.02E, 06/03
Page 37
STEP 40
Insert the pump relief spring (23A) between the lube
pump and input shaft.
STEP 41
The lube pump is driven by the input shaft. A roll pin in the
outer 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.
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 specified in "STARTING"
procedures of the "INSTALLATION" section. Check for
freedom of rotation after the pump is completely
assembled.
Gearbox
Item No.
905H
905L
905M, N
905T
909B
---
Location
Oil Filter Manifold
Gearbox Seal
Journal Bearings
Chemical Barrier Gasket
Gearbox Halves
Sight Glass
Size
3/8 - 16 x 1/2
1/4 -20 x 1/2
#10 - 24 x 1
1/4 - 20 x 5/8
3/8 - 16 x 2 1/2
#8 - 32 x 1/2
Item No.
3
905E
905F
905G
914A
914A
--905P
Location
Impeller Bolt/Inducer
Mechanical Seal No. Spacer
Throttle Bushing/Mechanical Seal
Double Seal with Spacer
Case Nuts
Case Nuts
Seal Housing to Gearbox
Separator
Torque Value
22 - 25 ft-lbs (30 - 34 N-m)
75 - 80 in-lbs (8.5 - 9.0 N-m)
35 - 40 in-lbs (4.0 - 4.5 N-m)
75 - 80 in-lbs (8.5 - 9.0 N-m)
40 - 45 ft-lbs (54 - 60 N-m)
20 - 22 in-lbs (2.3 - 25. N-m)
Pump
Size
1/2 - 20
1/4 - 20 x 12
1/4 - 20 x 12
1/4 - 20 x 3/4
3/4 - 10
7/8 - 9
3/8 - 16 x 1 3/4
1/2 - 20 x 5/8
Torque Value*
36 - 40 ft-lbs (49 - 54 N-m)
95 - 102 in-lbs (11 - 12 N-m)
95 - 102 in-lbs (11 - 12 N-m)
95 - 102 in-lbs (11 - 12 N-m)
250 - 275 ft-lbs (340 - 370 N-m)
300 - 330 ft-lbs (410 - 450 N-m)
35 - 40 ft-lbs (48 - 54 N-m)
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.
02.09.02E, 06/03
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 43
Assemble the input housing to the output housing.
Reseat locating pins (918M).
Torque cap screws (909B) and nut (914E) per Figure 15.
STEP 44
Install a new shaft seal (115) using a special tool
available from the factory. (Tool P/N TO06AA47).
During reassembly lubricate the lip of the new shaft seal
(115) and the outside diameter of the input shaft with
grease or oil.
02.09.02E, 06/03
Page 39
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 to
installation of the lip seal. Use caution to prevent
damage to the seal.
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.
Reassemble the pump to the gearbox in the reverse
order to disassembly.
Page 40
02.09.02E, 06/03
GENERAL
PARTS LIST
REPAIR KITS
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.
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.
02.09.02E, 06/03
Page 41
(177) VALVE
(110) INTERCONNECTING
SHAFT
*(936M) O-RING
PACKING (2)
(193C) PRESSURE
VALVE
(936K) O-RING
PACKING
(115) SHAFT
SEAL
(GEARBOX)*
(125C) RADIAL
BALL
BEARING
(916Z)
WASHER
(123A) SHAFT
SPACER
(905N)
HEX HEAD
CAP
SCREW
(123A) SHAFT
SPACER
(151B) JOURNAL
BEARING, UPPER
A
(924D) BULL
PLUG (2)
(918D) PIN
(155B) THRUST
WASHER, UPPER
(905F) HEX HEAD CAP SCREW (3)
(133B) THRUST
RUNNER
(122A) SPUR
GEAR
(120) LOW
SPEED SHAFT
(936H) O-RING
PACKING
(101B) GEARBOX
HOUSING (INPUT)
(920F) KEY
(920B) KEY
(920A) KEY
(125D)
RADIAL BALL
BEARING
(936A) O-RING
PACKING*
(123A)
SHAFT SPACER
(120) LOW
SPEED SHAFT
(2) IMPELLER
(10) STUD
(5) IMPELLER TAB WASHER*
(9) INDUCER
(OPTIONAL)
(60A)
MECHANICAL
SEAL
(23A) LUBE
PUMP
SPRING
(105)
HOUSING
GASKET
(160) LUBE
PUMP
(155A)
THRUST WASHER,
LOWER
(19A) SEAL
RETAINER SPACER
(943A)
CAP
(936T) O-RING
PACKING*
(971A) NIPPLE
(936H) O-RING
PACKING
(174D)
LUBE
JET
(87A) HOUSING
GASKET
(924B)
BULL PLUG (2)
(914A) NUT (6)
02.09.02E, 06/03
Page 42
Sundyne LMV-322
Figure 16
Optional
Dual Pressurized
(Double) Seal
Optional
Internal Centrifugal
Separator
Page 43
Optional
Dual Pressurized
(Tandem) Seal
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.
Optional
Inducer
02.09.02E, 06/03
Item Name
19A
21B
50
51A
52
60A
61A
62A
Part Name
Qty.
1
1
1*
1*
1
1*
1
1**
Item Name
63A
64A
65A
68A
905F
916B
936H
936G
936H
936J
936K
Part Name
- Seal Spring Backup Disc
- Seal Retaining Ring
- Seal Spring
- Seal Wedge Ring***
Hex Head Cap Screw
Washer
O-Ring Packing
O-Ring Packing
O-Ring Packing
O-Ring Packing
O-Ring Packing
Qty.
1**
1**
6**
1**
3
3
3*
1*
3*
2*
1*
02.09.02E, 06/03
Page 44
Item Name
19A
50A
50B
51C
52
60A
61A
62A
63A
64A
65A
68A
60B
Part Name
Qty.
1
1
1*
1*
1
1*
1
1**
1**
1**
6**
1**
1*
Item Name
61B
62B
63B
64B
65B
68B
905F
916B
936G
936H
936J
936K
Part Name
Qty.
1
1**
1**
1**
6**
1**
3
3
1*
3*
2*
1*
Page 45
02.09.02E, 06/03
936K
936H
936G
936J
ALTERNATE TWO PIECE UPPER SEAL
ROTATING FACE (REPLACING 51B)
Item Name
19A
50A
50B
51A
51B
51C
52
60A
61A
62A
63A
64A
65A
68A
60B
61B
62B
Part Name
Qty.
1
1
1*
1*
1*
1*
1
1*
1
1**
1**
1**
6**
1**
1*
1**
1**
Item Name
Part Name
Qty.
63A
64A
65A
68A
60B
61B
62B
65B
68B
69B
905F
916B
936G
936H
936J
936K
1**
1**
6**
1**
1*
1**
1**
1**
2**
1**
3
3
1*
3*
2*
1*
Page 46
101A (REF)
30 (REF)
2 (REF)
5 (REF)
10
9
Item Name
9
10
Part Name
Inducer
Inducer Stud
Qty.
1
1
Item Name
Part Name
Qty.
116
117
Input Coupling
118
Coupling Housing
119
Hub
904A
Screw
905J
909D
Bolt
914D
Nut
914H
Nut
916E
Washer
916M
Washer
916R
Washer
916Y
Washer
920E
Key
02.09.02E, 06/03
Item Name
Part Name
Qty.
106
1*
107
Seal Spacer
905T
916V
Seal Washer
3*
* Recommended Spares
101A (REF)
107
916V
106
905T
130 (REF)
93
Item Name
93
Discharge Piping
Part Name
Discharge Orifice
Qty.
1
Page 48
Item Name
185
190A
193
924M
950A
Part Name
Qty.
Oil Filter
Heat Exchanger
Temperature Gage
Pipe Plug
Elbow, Female Union
1
1
1
1
1
Item Name
950B
951D
951E
951F
951L
Part Name
Qty.
1
1
1
1
1
Item Name
90
Part Name
Separator Orifice
Qty.
1
91
Separator Fitting
905P
916L
Washer
918L
Pin (Alignment)
936U
O-Ring Packing
1*
936V
O-Ring Packing
1*
936Z
O-Ring Packing
1*
02.09.02E, 06/03
TROUBLESHOOTING
1. GEARBOX AND PUMP
Pump performance characteristics are shown on the
specification sheet and performance curve. Table 3
presents information which is useful in the analysis of
TROUBLE
No flow, no pressure
at start-up.
Insufficient flow or
head rise.
POSSIBLE CAUSE
INVESTIGATIVE/CORRECTIVE ACTION
Calibrate instrumentation.
Page 50
TROUBLE
POSSIBLE CAUSE
INVESTIGATIVE/CORRECTIVE ACTION
Insufficient NPSH.
Driver overloaded.
Excessive discharge
pressure pulsations
Page 51
02.09.02E, 06/03
TROUBLE
Sudden increase
seal leakage.
POSSIBLE CAUSE
INVESTIGATIVE/CORRECTIVE ACTION
Use single seal with throttle bushing and purge of dry nitrogen.
Install double or tandem seal if ice is caused by water in process
fluid, or supply external seal flush of compatible fluid which does
not contain water.
Worn or damaged seal.
Replace seal.
02.09.02E, 06/03
Page 52
SUNDYNE
14845 W. 64th Avenue o Arvada, Colorado 80007 USA o +1-303-425-0800 o FAX: +1-303-425-0896 o www.sundyne.com
Sundyne Europe o Longvic Cedex, France o +33-380-383300 o Fax +33-380-383371 o e-mail: european-sales@sundyne.com
ANSIMAG