Maintenance Manual

2368.8000/A11-14 G2 (01/19/10) LCC

LCC – Metal LCC – Rubber

Pump Type:
Pump Serial Number:
Date:
Purchaser:
Purchaser’s Order Number:
GIW Work Order Number:
Shipped To:

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

Note: This is a standard maintenance manual provided for your convenience.

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

GIW INDUSTRIES, INC. KSB AG

5000 Wrightsboro Road Johann-Klein-Str. 9
Grovetown, GA 30813 USA D-67227 Frankenthal, Germany
+1 (706) 863-1011 +49 6233 86-0 .
FAX +1 (706) 855-5151 FAX +49 6233 86-3289
www.giwindustries.com www.ksb.com

A KSB Company
 LCC
Contents
Section Page Section Page

1  General 4  6.3  Shutdown / Storage / Preservation 13 

6.3.1  Storage of New Pumps 13 
2  Safety 4  6.3.2  Measures to be taken for Prolonged Shutdown 13 
2.1  Marking of Instructions in the Manual 4  6.3.3  Storage of Elastomer Linings 13 
2.2  Personnel Qualification and Training 4  6.4  Returning to Service after Storage 14 
2.3  Non-compliance with Safety Instructions 4 
2.4  Safety Awareness 4  7  Maintenance /Repair 14 
2.5  Safety Instructions for the Operator / User 4  7.1  General Instructions 14 
2.6  Safety Instructions for Maintenance, Inspection 7.2  Maintenance / Inspection 14 
and Installation 4  7.2.1  Supervision of Operation 14 
2.7  Unauthorized Modification and Manufacture of 7.2.2  Lubrication and Lubricant Change 14 
Spare Parts 5  7.2.2.1  Lubrication 14 
2.8  Unauthorized Modes of Operation 5  7.2.2.2  Grease Quality / Grease Changes 14 
7.2.2.3  Oil Changes 14 
3  Transport and Interim Storage 5  7.3  Drainage / Disposal 15 
3.1  Transport 5  7.4  Dismantling 15 
3.2  Short Term Storage 5  7.4.1  Sectional Drawings and Bills of Material 15 
7.4.2  Dismantling Procedures Impeller 15 
4  Description 6  7.5  Reassembly 16 
4.1  Technical Specification 6  7.5.1  General Instructions 16 
4.2  Designation 6  7.5.2  Mounting Radial Bearing 17 
4.3  Design Details 6  7.5.4  Installing End Covers and Seals 20 
4.3.1  Pump Casing 6  7.5.5  Mounting Shaft Sleeve 21 
4.3.2  Impeller Form 6  7.5.6  Mounting Stuffing Box 21 
4.3.3  Shaft Seal 7  7.5.6.1  Stuffing Box 21 
4.3.4  Bearings 8  7.5.6.2   Packing (non-expeller) 21 
4.3.5  Permissible Forces and Moments at the Pump 7.5.6.3  Packing (expeller) 21 
Nozzles 9  7.5.7  Mounting the Bearing Assembly to Pedestal 21 
4.3.6  Noise Characteristics 9  7.5.8  Metal Expeller Assembly 21 
4.5  Dimensions and Weights 9  7.5.9  Mounting Shell 22 
7.5.10  Elastomer Lined Wet End 22 
5  Installation at Site 10  7.5.11  Impeller 22 
5.1  Safety Regulations 10  7.5.12  Suction Plate and Liner (LCC-H only) 22 
5.2  Foundation 10  7.5.13  Axial Adjustment of the Bearing Housing 22 
5.3  Installing the Pump / Unit 10  7.5.14  Expeller Running Clearance 23 
5.3.1  Aligning the Pump / Drive Train 10  7.5.15  Tightening Torques 23 
5.3.2  Place of Installation 10  7.5.16  Water Purge for Gland Packing 23 
. 11  7.6  Spare Parts Stock 24 
5.4  Connecting the Piping 11  7.6.1 Maintenance Procedures for Maximum Parts Life 24 
5.4.1  Auxiliary Connections 11  7.7  Operational Problems and Solutions 25 
5.4.2  Safety Guards 11 
5.5  Final Check 11  8  Trouble Shooting 27 
5.6  Connection to Power Supply 11 
9  Torque Values for Metric Fasteners 28 
6  Commissioning, Start-up / Shutdown 11 
6.1  Commissioning 11  NOTES 29 
6.1.1  Lubricants 11 
6.1.2  Shaft Seal Packing 12  10  General Drawing with List of Components 30 
6.1.3  Priming the Pump and Other Checks 12 
6.1.4  Checking the Direction of Rotation 12  11  Supplements 30 
6.1.5  Cleaning the Plant Piping 12  11. 1  Stuffing Box Throat Bushing Option 30 
6.1.6  Suction Strainer 12  11.2   Underwater Pump Operation with Duo-Cone
6.1.7  Start-up 13  Bearing Seals 30 
6.1.8  Shutdown 13  11.1  Stuffing Box Throat Bushing Option 31 
6.2  Operating Limits 13  11.2  Underwater Pump Operation with Duo-Cone
6.2.1  Temperature of the Medium Handled, Ambient Bearing Seals 32 
Temperature, Bearing Temperature 13  11.3  Duo-Cone Seals 33 
6.2.2  Switching Frequency 13  11.4  Diverter 35 
6.2.3  Density of the Medium Handled 13 

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Index
Section Page Section Page

Accessories 4.4 9 Operation, Supervision of 7.2.1 14

Aligning the Pump / Drive Train 5.3.1 10 Operation, Unauthorized modes 2.8 5
Bearing Assembly Clamp Bolts 7.5.15 23 Operational Problems and Solutions 7.7 24, 25
Bearing Assembly, Mounting 7.5.7 21 Packing the gland 7.5.16 23
Bearing Housing, Axial Adjustment of 7.5.13 22 Personnel Qualification and Training 2.2 4
Bearing, Taper Locknut Assembly Torque 7.5.15 23 Piping System Design 7.7 25
Bearings 4.3.4 8 Piping, Allowable Forces and Moments 4.3.5 9
Bearings, mounting 7.5.2 17 Piping, Cleaning the Plant 6.1.5 12
Bills of Material 7.4.1 15 Power Supply, Connection 5.6 11
Casing 4.3.1 6 Priming the Pump and Other Checks 6.1.3 12
Cavitation / NPSH Performance 7.7 25 Reassembly , General Instructions 7.5.1 16
Check, Final 5.5 11 Reassembly 7.5 16
Commissioning 6.1 11 Safety 2 4
Commissioning 6 11 Safety Awareness 2.4 4
Connections, Auxiliary 5.4.1 11 Safety Instructions for the Operator / User 2.5 4
Density of the Medium Handled 6.2.3 13 Safety Instructions, for Maintenance 2.6 4
Description 4 6 Safety Instructions, Non-compliance with 2.3 4
Design Details 4.3 6 Safety Regulations 5.1 10
Dimensions 4.5 9 Seal Water Requirements 7.5.16 24
Dismantling 7. 15 Shaft Seal 4.3.3 7
Drainage / Disposal 7.3 15 Shaft Seal, Commissioning 6.1.2 12
Drawing / List of Components 9 30 Shaft Sleeve, Mounting 7.5.5 21
Drawings , Sectional 7.4.1 15 Shell, Mounting 7.5.9 22
Elastomer Lined Wet End, Assembly 7.5.10 22 Shell, Parts Life 7.6.1 24
End Covers and Seals, installation 7.5.4 20 Shutdown / Storage / Preservation 6.3 13
Expeller Running Clearance 7.5.14 23 Shutdown 6.1.8 13
General 1 4 Shutdown, Prolonged 6.3.2 13
Grease Quality / Grease Changes 7.2.2.2 14 Spare Parts Stock 7.6 24
Guards, Safety 5.4. 11 Spare Parts, Unauthorized Modification of 2.7 5
Impeller Break-Loose Jig 7.4.2 15 Specifications 4.1 6
Impeller Form 4.3.2 6 Start-up Strainer 6.1.6 12
Impeller Lifting Jig 7.4.2 15 Storage of Elastomer Linings 6.3.3 13
Impeller, Mounting 7.5.11 22 Storage of New Pumps 6.3.1 13
Impeller, parts life 7.6.1 24 Storage, Returning to Service after 6.4 14
Installation at Site 5 10 Storage, Short term 3.2 5
Installation, Checks to be Carried out Prior to 5.2 10 Stuffing Box, Mounting 7.5.6 21
Installing the Pump / Unit 5.3 10 Suction Liner, parts life 7.6.1 24
Lubricants 6.1.1 11 Suction Plate and Liner (LCC-H only) 7.5.12 22
Lubrication 7.2.2.1 14 Sump Design 7.7 25
Lubrication and Lubricant Change 7.2.2 14 Switching Frequency 6.2.2 13
Maintenance / Inspection 7.2 14 Temperature, of the Medium Handled Ambient 6.2.1 13
Maintenance /Repair 7 14 Transport 3.1 5
Maintenance, General Instructions 7.1 14 Transport and Interim Storage 3 5
Marking of Instructions in the Manual 2.1 4 Trouble Shooting 8 27
Noise Characteristics 4.3.6 9 Wear Problems and Solutions 7.7 25
Oil Changes 7.2.2.3 14 Wear, Parts Life 7.6.1 24
Operating Conditions of Flow and Head 7.7 25 Weights 4.5 9
Operating Limits 6.2 13

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

The electrical danger warning sign is 2.6 Safety Instructions for Maintenance,
the safety sign in accordance with DIN Inspection and Installation
4844-W8. The operator is responsible for ensuring that all
maintenance, inspection and installation work is performed
The word caution is to introduce safety by authorized and qualified personnel who are thoroughly
instructions whose non-observance familiar with the manual.
may lead to damage to the machine
and its functions. Work on the machine must be carried out only during
standstill. The shutdown procedure described in the
Instructions attached directly to the machine, such as: manual for taking the machine out of service must be
• Arrow indicating the direction of rotation adhered to without fail.
• Marking for fluid connections must always be
complied with and be kept in legible condition at all Pumps or pump units handling media injurious to health
times. must be decontaminated.

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Immediately following completion of the work, all safety /
protective devices must be re-installed and / or re-
activated.

Please observe all instructions set out in the chapter on

“Commissioning” before returning the machine to service.

2.7 Unauthorized Modification and Manufacture

of Spare Parts
Modifications or alterations of the machine are only
permitted after consultation with the manufacturer. Original
spare parts and accessories authorized by the
manufacturer ensure safety. The use of other parts can
invalidate any liability of the manufacturer for damage or Fig. 3.1-1 Transport of the pump
warranty.

2.8 Unauthorized Modes of Operation

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

3 Transport and Interim Storage

3.1 Transport
Proper lifting and safety practices must be observed at all
times. Lifting the pump assembly requires extreme care,
since the center of gravity is not located in the physical
center of the unit, but is usually closer to the stuffing box /
shaft seal area.

Never lift by a single point and do not use the pump or WARNING: Very top heavy
motor shaft as a lift point. Eyebolt locations on the bearing Fig. 3.1-2 Transport of the complete unit
assembly and motor are intended for lifting those items
only and must not be used to lift the pump assembly. 3.2 Short Term Storage
The pump / unit should be stored in a dry room where the
At least four (4) connections are recommended to stabilize atmospheric humidity is as constant as possible.
the load, and they should be as far apart as practical.
Avoid excessive side loads on cast lifting eyes. Note that If stored outdoors, the unit and crates must be covered by
certain lift points on the pedestal are intended for use in waterproof material to avoid any contact with humidity.
handling the pedestal alone and are not necessarily
optimum balance points for the pump assembly. All openings of the assembled pump / unit components
are closed and must only be opened when required during
Always make sure that the unit remains in the horizontal installation.
position during transport and cannot slip out of the
transport suspension arrangement. Protect all stored goods against humidity,
Caution
dirt, vermin and unauthorized access!
If the pump / unit slips out of the suspension
arrangement, it may cause personal injury and Short term storage requirements are defined for up to 3
damage to property. months. For storage exceeding 3 months see Section 6.3
on long term storage requirements.
Figures below give suggested lifting methods. Actual safe
lifting method will vary with pump configuration and type of
lifting equipment. Ensure secure attachments and test
lifting method for stability before moving pump.

In corrosive environments be sure to remove all lifting

devices from the pump and store in a non-corrosive
environment until needed.

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4 Description 4.3.1 Pump Casing
4.1 Technical Specification Three standard configurations are available:
Centrifugal pump for handling coarse or fine particles from
solids-laden waste water to aggressive slurries of an 1 Hard Metal. Single-wall casing, impeller and suction
abrasive or corrosive nature. liner of high-chrome white iron. Suitable for high-discharge
head, all particle sizes up to maximum sphere passage
Applications include process pumping and tailings and mildly corrosive slurries. Custom materials available
disposal for mining, dredging and other industrial for highly corrosive slurries.
operations.
2 Elastomer Lined. Radially split construction with ductile
4.2 Designation iron outer casing and molded-elastomer inner liners.
LCC-M 300-710.5M C M1 Impeller of high chrome white iron or polyurethane. For
Pump Type moderate discharge head, fine to medium particles and
Hydraulic Type highly corrosive slurries.
Discharge Nozzle (mm)
Nominal Impeller Diameter (mm) 3 Extra Heavy Hard Metal. Similar to hard metal
Mechanical Size version, but with heavier sections and hydraulics suited to
Seal Type the most severe slurry duties. Two-stage pressure
Options capability. Available in sizes LCC 150 - 500 and above.
Material Code
All casings carry 125 pound, ANSI flange bolting patterns.
Hydraulic Type Adapters for conversion to DIN flanges are available.
M Metal
R Rubber
H Heavy Construction

Mechanical (Frame) Size

1 2 3 4 5
35 mm 50 mm 70 mm 100 mm 125 mm

Seal Type
K KE
B Throat Bushing
M Mechanical Seal
E Expeller

Options Figure 4.3-1 LCC Hard Metal Wet End

O Open Shroud Impeller
AF Oil Lubricated Face to Face
AB Oil Lubricated Back to Back
UF Underwater Oil Lubricated Face to Face
UB Underwater Oil Lubricated Back to Back
GF Grease Lubricated Face to Face
GB Grease Lubricated Back to Back
T Turn Down Impeller
C Elastomer Impeller

Material Code
M1 Metal
MC2 Metal / Chemical
R1 Rubber
Figure 4.3-2 LCC Elastomer-Lined Wet End
Nominal Flange and Impeller Diameters in mm (inches)
Designation Discharge Suction Impeller
LCC 50 - 230 50 ( 2”) 80 ( 3” ) 225 ( 8.86” )
LCC 80 - 300 80 ( 3” ) 100 ( 4” ) 310 ( 12.22”)
LCC 100 - 400 100 ( 4” ) 150 ( 6” ) 395 ( 15.55”)
LCC 150 - 500 150 ( 6” ) 200 ( 8” ) 500 ( 19.69” )
LCC 200 - 610 200 ( 8” ) 250 ( 10”) 610 ( 24” )
LCC 250 - 660 250 (10”) 300 ( 12”) 660 ( 26” )
LCC 300 - 710 300 ( 12”) 350 ( 14”) 710 ( 27.95”)

4.3 Design Details

Horizontal, end suction, modified volute casing pump with
three-vane impeller for large solids passage. Available in
interchangeable elastomer, metal and extra-heavy
designs. Figure 4.3-3 LCC Extra Heavy Hard Metal Wet End

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shrouded and alternate vane number designs are which must be accounted for during motor selection.
available in some sizes. Changes to head, flow, pump speed, process solids or
sump level after the pump has been installed can affect
4.3.3 Shaft Seal the functionality of an expeller sealing system.
All standard pumps use replaceable gland packing in a
stuffing box with connections for flush water or sealing Correct installation, adjustment and operating procedures
liquid. Options include throat bushing, slurry duty are extremely critical to the proper function and life of
mechanical seals or expeller with grease lubricated gland these seals. Extensive testing has shown that the
packing. following guidelines can help keep the expeller system
operating properly while prolonging the life of wear
components. Further engineering review is recommended
for expeller operation outside these guidelines.

Particle size – The D50 should be kept between 200 and

1500 microns.
Throat Bushing Option
Slurry SG – The Specific Gravity of the slurry should
remain below 1.35.

Solids – Slurries that could deposit scale on pump

surfaces should be avoided.

Flow rate – Stay between 0.5 and 1.3 times the Best
Fig 4.3-4 Gland Packing (non-expeller) Efficiency Point (QBEP).

Flushing – Solids in the process flow can precipitate out

when the pump stops and build up in the expeller
chamber. Over time, this reduces efficiency and
accelerates wear. The system should always be purged
with clear water for at least 15 minutes prior to stopping
the pump. Starting the system on clear water will help the
expeller displace solids. For applications where precipitate
buildup in the expeller chamber is unavoidable,
intermittent gland water flush may be necessary.

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

New expeller pumps are equipped with a diverter ring

pressed into the hub area of the pump casing. This acts as
a baffle to help reduce the amount of solids entering the
seal chamber. The diverter can be ordered as a service
part and retrofit into earlier units. For diverter installation
Fig 4.3-5 Typical Expeller Arrangement see supplement 11.4.
Expeller seals are used in pump applications where limited It is important to operate the expeller pump within the
or no gland flush water is readily available or where it is speed limitations and operating conditions specified in the
not compatible with the process fluid. A second rotating original design parameters. Wide variations in flow rate
impeller contained in a separate casing creates a lower and solids can allow particles to accumulate in the expeller
pressure at the stuffing box seal area. This allows the chamber, which may result in a plugging or premature
shaft sleeve to be grease lubricated and run with only component failure. Any change in the operating conditions
enough packing compression to seal the pump. should be discussed with your GIW / KSB representative
to establish if the new conditions are suitable for the
Unlike mechanical seals, expellers must be carefully equipment.
selected for each application and specific operating
conditions. Expellers require additional driver horsepower,
7
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4.3.4 Bearings
The bearing assembly is a cartridge design mounted on a
concentric pedestal with an adjustment mechanism for
setting the impeller axial clearance.
Standard lubrication is grease. Oil lube is also available.
For lubrication quality and quantity, see Section 7.2.

Basic bearing parts are listed below for reference. Note

that the suffix can vary depending on configuration and
vendor. Replacement bearings are available from
Fig 4.3-6 Typical Slurry Mechanical Seal GIW/KSB.

For information on mechanical seals, consult the

manufacturer’s manual.

Bearings Installed
Double Row Taper Roller - Back to Back Double Row Taper Roller - Face to Face
Bearing Spherical
Assembly Roller Part number Bench Part Number Bench
(Timken) End-Play (SKF) End-Play
E Type Cone / Cup / Spacer * mm (inch) mm (inch)
53177
35 mm 22209E 53376D 0.15 (0.006) 31309 J2/QCL7CDF 0.10 (0.004)
X2S53176
72225C
50 mm 22212E 72488D 0.15 (0.006) 31312 J2/QDF 0.12 (0.005)
X1S72225
9285
70 mm 22217E 9220D 0.18 (0.007) 31316 J1/QLC7CDF 0.14 (0.006)
X4S9285
HM926740
100 mm 22224E HM926710CD 0.25 (0.010) 31322 XJ2/DF 0.16 (0.006)
HM92674XA
HH932145
125 mm 22230E HH932110 0.20 (0.008) 31328 XJ2/DF 0.19 (0.008)
H932145XA **
* Koyo is also an approved supplier for the Back to Back Taper roller bearing.
** Assembled from two single row bearings.

Fig 4.3-7.1 Cartridge Bearing Assembly

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4.3.5 Permissible Forces and Moments at the Pump
Nozzles
Allowable combined branch loads applicable for all GIW
slurry pumps. Methods based on ANSI/HI 12.1-12.6-2005
Slurry Pump Standard. Coordinate system per HI/ANSI
9.6.2 and API 610 (see figure). Loads generally exceed
HI/ANSI 9.6.2-2008 table 9.6.2.1.4a and API 610-2004,
Table 4. Higher allowable loads may be possible
depending on individual pump configuration and operating
conditions. Contact your GIW Application Engineer for
more information.

Allowable Forces Allowable Moments

Flange
Size FX FY FZ MX MY MZ
lbs (N) lbs (N) lbs (N) ft-lbs (N-m) ft-lbs (N-m) ft-lbs (N-m)
2 inch
2490 (11070) 1980 (8800) 3000 (13340) 2640 (3570) 2640 (3570) 4000 (5420)
(50 mm)
3 inch
2730 (12170) 2170 (9680) 3290 (14670) 2900 (3930) 2900 (3930) 4390 (5960)
(75 mm)
4 inch
DISCHARGE PIPE

2980 (13270) 2370 (10550) 3590 (15990) 3160 (4290) 3160 (4290) 4790 (6500)
(100 mm)
6 inch
3470 (15440) 2760 (12280) 4180 (18610) 3680 (4990) 3680 (4990) 5580 (7570)
(150 mm)
8 inch
3950 (17580) 3140 (13980) 4760 (21190) 4200 (5690) 4200 (5690) 6360 (8620)
(200 mm)
10 inch
4420 (19690) 3520 (15660) 5330 (23730) 4700 (6380) 4700 (6380) 7130 (9670)
(250 mm)
12 inch
4890 (21780) 3890 (17320) 5900 (26240) 5210 (7070) 5210 (7070) 7900 (10710)
(300 mm)
14 inch
5350 (23830) 4260 (18950) 6450 (28710) 5710 (7740) 5710 (7740) 8650 (11730)
(350 mm)
3 inch
3290 (14670) 2730 (12170) 2170 (9680) 4390 (5960) 2900 (3930) 2900 (3930)
(75 mm)
4 inch
3590 (15990) 2980 (13270) 2370 (10550) 4790 (6500) 3160 (4290) 3160 (4290)
(100 mm)
SUCTION PIPE

6 inch
4180 (18610) 3470 (15440) 2760 (12280) 5580 (7570) 3680 (4990) 3680 (4990)
(150 mm)
8 inch
4760 (21190) 3950 (17580) 3140 (13980) 6360 (8620) 4200 (5690) 4200 (5690)
(200 mm)
10 inch
5330 (23730) 4420 (19690) 3520 (15660) 7130 (9670) 4700 (6380) 4700 (6380)
(250 mm)
12 inch
5900 (26240) 4890 (21780) 3890 (17320) 7900 (10710) 5210 (7070) 5210 (7070)
(300 mm)
14 inch
6450 (28710) 5350 (23830) 4260 (18950) 8650 (11730) 5710 (7740) 5710 (7740)
(350 mm)

4.3.6 Noise Characteristics between units. For belt driven units, add an additional 2
If running within the normal limits of operation and on clear dB.
liquid, the sound pressure level for the pump alone does
not exceed 80 dB at one meter. 4.4 Accessories
Couplings, pulleys, belts, motor mounts and/or base plates
The addition of coarse solids, froth or cavitating may be provided. Refer to the bill-of-materials, data sheets
conditions can significantly increase the noise and/or drawings for further information.
levels in both the pump and piping. If accurate noise levels
are required for these conditions, field-testing will be 4.5 Dimensions and Weights
required. Dimensions and weights are listed on the pump
installation plan.
Sound pressure levels from motor and gear reducer must
be added to the above in accordance with standard
acoustic formulas, taking into account the distance

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5 Installation at Site Use of the mounting bolts to close gaps between
5.1 Safety Regulations motor feet and the mounting plate (in place of
Electrical equipment operated in hazardous shimming) is not recommended and may result in twisting
locations must comply with the applicable of the motor frame, “soft foot” mounting and excessive
explosion protection regulations. This is indicated on the vibration.
motor rating plate. If the equipment is installed in
hazardous locations, the applicable local explosion Coupling check and realignment must be done even if
protection regulations and the regulations of the test pump and motor are supplied completely assembled and
certificate supplied with the equipment and issued by the aligned on a common base plate. The correct distance
responsible approval authorities must be observed and between the coupling halves as specified in the installation
complied with. The test certificate must be kept close to plan must be observed.
the location of operation for easy access (e.g. foreman’s
office). The pump set is correctly aligned if a straight-edge placed
axially on both coupling halves is the same distance from
5.2 Foundation each shaft at all points around the circumference. In
All structural work required must have been prepared in addition, the distance between the two coupling halves
accordance with the dimensions stated in the dimension must remain the same all around the circumference. Use a
table / installation plan. feeler gauge, a wedge gauge or a dial micrometer to verify
(see Figures 5.3.2 and 5.3.3).
The concrete foundation shall have sufficient strength for
the pump and be completely cured before installation. The Straight edge
mounting surface must be flat and level. Anchor bolts must
be located according to the installation plan. This can be
done when the concrete is poured, or by drilling holes in
existing foundations and grouting the bolts in place. a b

5.3 Installing the Pump / Unit

After placing the base plate on the foundation, it must be
leveled by shimming. Shims should be fitted between the a b
base plate and the foundation itself; they should always be
inserted to the left and right of the foundation bolts and in
close proximity to these bolts. For a bolt-to-bolt clearance Gauge
Straight edge
of more than 800mm (30 in.), additional shims should be
inserted halfway between the adjoining holes. All shims Fig. 5.3-2: Aligning the coupling with the help of a gauge
must lie perfectly flush. and a straight-edge

Insert the foundation bolts and set them into the The radial and axial deviation (tolerance) between the two
foundation using concrete. When the mortar has set, coupling halves should not exceed 0.1 mm (0.004 inch).
tighten the foundation bolts evenly and firmly and grout the
base plate using low shrinkage grout. Improper alignment of the unit can cause damage
to both the coupling and the unit itself!
Shim Shim Shim
For V-belt installations, the pulleys are correctly aligned if
≤ 800 a straight-edge placed vertically shows a deviation of no
more than 1.0 mm (0.04 in.). Both pulleys must be parallel.

Foundation bolts
Fig. 5.3-1: Fitting required shims (mm)

5.3.1 Aligning the Pump / Drive Train align max. 1mm

All components must be level during
Caution
operation unless special provisions for Fig. 5.3-3 Aligning of V-belt pulleys
bearing lubrication and oil sealing have been made. After
attaching the unit to the foundation and connecting the 5.3.2 Place of Installation
piping, the pump and drive train must be thoroughly The volute casing and the mechanical seal (if
checked and, if necessary, realigned equipped) take on approximately the same
temperature as the pump fluid. The mechanical seal (if
Proper alignment must be taken into consideration when equipped), bearing assembly and bearing housing must
using the overhead motor mount accessory. Motor feet not be insulated.
must be firmly supported at each mounting bolt location
before the bolts are tightened. Shims should be used to fill Take the necessary precautions to avoid burns to
any gaps and ensure solid mounting and vibration personnel and adjacent equipment.
prevention.

10
 LCC
•
.

5.4 Connecting the Piping Make sure the unit is properly connected to the
Never use the pump itself as an electric power supply and is equipped with all
Caution protection devices.
anchorage point for the piping. The
permissible pipeline forces must not be exceeded (see • Make sure all auxiliary connections (5.4.1) are
Section 4.3.5). connected and functioning.
• If the pump has been out of service for a long period
Thermal expansions of the pipelines must be of time, proceed in accordance with Section 6.4.
compensated by appropriate measures so as not to
impose any extra loads on the pump exceeding the 6.1.1 Lubricants
permissible pipeline forces and moments. Grease Lubricated Bearings
Grease lubricated bearings are packed with grease at the
An excessive, impermissible increase in the pipeline factory. They should be re-lubricated after the initial 50
forces may cause leaks on the pump where the medium hours of operation, and at regular intervals thereafter. See
handled can escape into the atmosphere. Section 7.2.2.2 for grease lubrication instructions.
If shaft speeds exceed those in the table below, the
Danger of life when toxic or hot media are bearing housing temperature should be monitored during
handled. commissioning and additional grease added if it exceeds
100oC (210oF), or if bearings are noisy . In some cases
The flange covers on the pump suction and discharge where external cooling of the housing is poor, it may be
nozzles must be removed prior to installation in the piping. necessary to stop and allow the bearings to cool several
times during this break-in period.
5.4.1 Auxiliary Connections
The dimensions and locations of the auxiliary connections
Bearing Assembly *Shaft Speed (rpm)
(cooling, heating, sealing liquid, flushing liquid, etc.) are
indicated on the installation plan or piping layout. 35mm 2300
50mm 1800
These connections are required for proper 70mm 1400
Caution 100mm 1000
functioning of the pump and are therefore
of vital importance! 125mm 750
*Monitor commission temperature is exceeded
5.4.2 Safety Guards
In compliance with the accident prevention Some lubricant may be expelled from the labyrinth oil
regulations the pump must not be operated without seals upon startup. This is normal and will stop once the
coupling and drive guards. If the customer specifically excess grease has been purged.
requests not to include guards in our delivery, then the
operator must supply them. Oil-lubricated bearings
Units may be shipped without oil from the factory. Fill with
5.5 Final Check the supplied GIW Blue 150 oil to the center of the sight
Re-check the alignment as described in Section 5.3. gauge.
It must be easy to rotate the shaft by hand at the coupling.
Before starting the pump, verify that the bearing assembly
5.6 Connection to Power Supply is correctly filled to the center of the oil level sight gauge.
A trained electrician must make the connection to the Do not overfill. Factory filled units contain GIW Blue ISO
power supply. Check available mains voltage against the 150 synthetic bearing oil. This is available as GIW part
data on the motor rating plate and select the appropriate number 690-9090P-01-B150P. Otherwise, use an
start-up method. equivalent synthetic or a high quality ISO220 mineral oil
suitable for use with heavy industrial equipment, anti-
We strongly recommend the use of a motor protection friction bearings and oil circulating systems. Such oil
device. typically has high temperature stability, resistance to
oxidation and foaming, and inhibits rust, corrosion, and the
6 Commissioning, Start-up / formation of deposits. Oils with EP additives are not
recommended.
Shutdown
Compliance with the following Typical oil operating temperatures for GIW bearing
Caution
requirements is of paramount importance. assemblies will run from 125 to 185°F (50 to 85°C),
Damage resulting from non-compliance shall not be depending on the pump size, speed and ambient
covered by the scope of warranty. conditions. For oil temperatures above 185°F (85°C) or for
severe load conditions, a high quality synthetic lubricant
This manual applies to single stage pumps. Procedures should be used. Contact your GIW/KSB representative for
for multistage pumps should be obtained from GIW/KSB a recommendation. At higher speeds, or in hotter ambient
sales office. conditions, temperatures can rise to 210°F (100°C).
Slightly higher temperatures may be seen for a brief
6.1 Commissioning period during the breaking in of new bearings. The unit
Before starting up the pump make sure that the following should be shut down immediately if temperatures rise to
requirements are checked and fulfilled. 250°F (120°C).
The operating data, the oil level, if required (6.1.1), the
nose clearance, and the direction of rotation (6.1.4) must
be checked. The pump set must be primed (6.1.3).

11
 LCC
For gland flush supply, use suitable non-aggressive clean
Approximate Oil Capacity water not liable to form deposits and not containing
Bearing Assembly suspended solids. Hardness should average 5 with a
liter quart
35 mm 0.75 0.75 ph>8. It should be conditioned and neutral with regard to
mechanical corrosion.
50 mm 1.0 1.0
70 mm 1.75 2.0 o o
An Inlet Temperature of 10 to 30 C (50 to 85 F) should
100 mm 3.0 3.25 produce a maximum Outlet Temperature 45 C (115 o F)
o
125 mm 6.0 6.5 when the gland is properly adjusted.

Do not overfill the bearing assembly. The capacities listed Running the pump dry will result in
above are approximate. When filling the bearing housing, Caution
increased wear on the gland packing and
the oil level must be at the centerline of the oil level sight shaft protecting sleeve or failure of the mechanical seal.
glass when the shaft is not turning. This is the ”cold level”
and will change as the pump runs and the oil becomes Mechanical Seals
suspended in the bearings. Mechanical seals are precision devices, which require
special care for their proper operation. If pump is equipped
The constant oil leveler is no longer available. It is not with a mechanical seal, the instruction manual for the seal
recommended for use since it can increase oil level should be consulted for special storage, startup and
when the pump is running and cause leaks at bearing maintenance requirements.
seals.
Mechanical seals require safety checks
Fill plug Caution
prior to start-up such as removing seal
assembly fixtures, checking axial alignment, etc. Refer to
the mechanical seal operating manual for all required
Oil level safety checks.
sight glass
6.1.3 Priming the Pump and Other Checks
Before start-up, the pump, suction line and (if applicable)
the tank must be vented and primed with the liquid to be
pumped. Any valve in the suction line must be fully open.

Open all auxiliary connections (flushing, sealing, cooling

liquid, etc.) and check the through flow.

6.1.4 Checking the Direction of Rotation

Oil level with The impeller must rotate in the direction
pump stopped Caution
indicated by the arrow on the pump
Drain plug
casing. This must be verified by briefly running the motor
Fig. 6.1.1: Oil fill, drain and level with the coupling or belt drive disconnected. If the motor
runs in the wrong direction of rotation, have it corrected
Underwater Operation and verify direction of rotation before reconnecting
Bearing assemblies for use underwater should be coupling or belts. If a Variable Frequency Drive (VFD) or
completely filled with oil and slightly pressurized by an oil other controller is used, it is recommended to permanently
recirculation and filtering system. As a result, their disable REVERSE and BRAKE function during controller
capacities will be several times greater than shown above set up.
and a thinner oil will be required. Depending upon the
water temperature at the location at which the pumps are If motive power is applied to the pump, and it is run in the
operating, the ISO viscosity grade should be altered as wrong direction of rotation, even momentarily, the impeller
follows for mineral oil-based lubricants: may unscrew causing extensive damage to the entire unit.
This is especially important during initial start up as the
Water Temperature ISO Viscosity Grade impeller may not be fully torqued onto the pump shaft.
0 to 20 oC (32 to 70 oF) 100
20 to 30 oC (70 to 85 oF) 150 6.1.5 Cleaning the Plant Piping
over 30 oC ( over 85 oF) 200 The cleaning operation mode and duration for
GIW Blue oil may be used for all the above temperatures flushing and pickling service must be matched to
the casing and seal materials used.
For more information on Underwater Bearing Assemblies
see section 11.2 and 11.3 6.1.6 Suction Strainer
If a suction strainer has been fitted to protect the pumps
6.1.2 Shaft Seal Packing against dirt and/or to retain contamination from the plant;
Prior to commissioning, the gland packing supplied with the strainer’s contamination level must be monitored by
the pump must be adjusted as described in Section measuring the differential pressure to ensure adequate
7.5.16. Preformed packing rings sets from GIW / KSB are inlet pressure for the pump.
recommended. For alternate brands, refer to packing
manufacturer’s instructions regarding installation and use
(see Section 2.7).

12
 LCC
6.1.7 Start-up
Before starting the pump, ensure that the Bearing temperatures, as described in Section 7.2.1, must
Caution
shut-off element in the suction line is fully be observed. Excessive bearing temperature could
open. The pump may be started up against a closed indicate misalignment or other technical problem.
discharge-side swing check valve or shut-off element.
Only after the pump has reached full rotational speed 6.2.2 Switching Frequency
should the shut-off be opened slowly and adjusted to To prevent high temperature increases in the motor and
comply with the duty point. When starting up against an excessive loads on the pump, coupling, motor, seals and
open discharge-side shut-off element, take the resulting bearings, the switching frequency should not exceed the
increase in input power into account. following number of start-ups per hour (h):

Prolonged operation against a closed shut-off Motor Rating maximum switching/hr

element is not permitted. Danger of steam up to 12kW (16hp) 25
generation and explosion! up to 100kW (135hp) 20
more than 100kW (135hp) 10
Once the operating temperature has been
Caution
reached and / or in the event of leakages,
switch off the unit and re-tighten all bolts. Check the 6.2.3 Density of the Medium Handled
coupling alignment as described in Section 5.3.1 and re- The power input of the pump will increase in proportion to
align, if necessary. the density of the medium handled. To avoid overloading
of the motor, pump and coupling, the density of the
6.1.8 Shutdown medium must comply with the data specified on the
Under no circumstances should the pipe system be purchase order.
equipped with a check valve or other device that can
rapidly decelerate the flow rate. 6.3 Shutdown / Storage / Preservation
Each GIW / KSB pump leaves the factory carefully
Switch off the drive, making sure that the unit runs assembled. If commissioning is to take place sometime
smoothly down to a complete stop. Variable Frequency after delivery, we recommend that the following measures
Drive (VFD) and other controllers must not use any be taken for pump storage exceeding 3 months.
braking function to slow the pump. Diesel power trains
should disengage the clutch and allow the pump to coast 6.3.1 Storage of New Pumps
to a stop. • Maximum protection for up to 12 months, if the pump
is properly stored indoors.
Close any auxiliary connections. Pressurized bearing • Store the pump in a dry location
lubrication systems must remain running until all rotation • Rotate the pump rotor by hand once a month.
has stopped. If the any part of the system uses a cooling • Follow manufacturer’s instructions for mechanical
liquid supply, turn that off only after the pump has cooled seals.
down. Where liquid filled shaft seals are used, consult seal • See requirements for rubber liner storage below.
maintenance manual for specific shutdown procedures.
6.3.2 Measures to be taken for Prolonged Shutdown
In the event of shutdown where a 1 The pump remains installed; operation check run
Caution In order to make sure that the pump is always ready
significant static discharge head exists in
the system, the impeller can begin to run backwards as for instant start-up and to prevent the formation of
the flow reverses in the pipeline. This creates a positive deposits within the pump and the pump intake area,
torque on the shaft so the impeller connection will not start up the pump set regularly once a month or once
unscrew. Until the flow stops, do not close any main line every 3 months for a short time (approx. 5 minutes)
valves. A change in fluid velocity can create a negative during prolonged shutdown periods. Prior to an
torque on the impeller and unscrew it from the shaft. This operation check run ensure that there is sufficient
can damage wet end pump parts as well as bearings, liquid available for operating the pump.
seals and other components
2 The pump is dismantled and stored
Where temperatures may drop below freezing, the pump Before putting the pump into storage carry out all
and system must be drained or otherwise protected checks specified in Sections 7.1 to 7.4. It is advisable
against freezing. to close the nozzles (for ex. with plastic caps or
similar).
6.2 Operating Limits
The pump’s / unit’s application limits regarding 6.3.3 Storage of Elastomer Linings
pressure, temperature and speed are stated on the Pumps with elastomer linings should be stored in a cool
data sheet and must be strictly adhered to. If a data sheet dark location free from electrical equipment such as
is not available, contact your GIW/KSB representative. motors, or any other ozone generating devices. Exposure
to direct sunlight or temperatures in excess of 50°C
6.2.1 Temperature of the Medium Handled, Ambient (120°F) must be avoided.
Temperature, Bearing Temperature
Do not operate the pump at temperatures exceeding those Properly stored elastomer parts will retain their properties
specified on the data sheet or the nameplate unless the for about two years for gum rubber, or five years for
written permission of the manufacturer has been obtained. neoprene or urethane. The parts should be periodically
inspected for the presence of a soft chalky layer, easily
Damage resulting from disregarding this warning will not rubbed off, which would indicate deterioration. Darkening
be covered by the manufacturer’s warranty. or discoloration of elastomer parts over time is a natural
13
 LCC
occurrence and does not by itself indicate any loss of
properties. The gland packing (if the pump is fitted with one) should
drip slightly during operation. The gland should only be
6.4 Returning to Service after Storage gently tightened.
Before returning the pump to service, carry out all checks
and maintenance work specified in Sections 7.1 and 7.2. Any stand-by pumps installed should be switched on and
off again once a week to keep them operational. Attention
The instructions given in the sections on should be paid to the correct functioning of the auxiliary
“Commissioning” (6.1) and “Operating Limits” (6.2) connections.
must be observed.
If the flexible coupling elements begin to
Caution
Upon completion of the work, all safety-related and show signs of wear, they should be
protective equipment must be properly refitted replaced.
and/or reactivated before starting the pump set.
7.2.2 Lubrication and Lubricant Change
7 Maintenance /Repair 7.2.2.1 Lubrication
7.1 General Instructions The rolling element bearings are lubricated with grease or
GIW Synthetic Blue 150. The lubricant change intervals as
The LCC pump range is an international product and has
well as the required quantity and quality are specified
been designed, in most respects, to the METRIC system
below.
of units using metric components. All fasteners are metric
and will require metric tooling. All seals are metric
Under severe operating conditions, high ambient
including oil seals, O-rings and stuffing box packing.
temperature, high humidity, dust laden air, aggressive
Two important exceptions: 1) The suction and discharge
industrial atmosphere, etc. the intervals for checking,
flange bolting patterns are to the American (ANSI)
replenishing and replacing the lubricant should be
standard, however, flange adapting spools are available.
shortened.
2) The drive end bearing is an inch based taper roller
bearing.
7.2.2.2 Grease Quality / Grease Changes
The bearings are packed with high-quality lithium-soap
The operator is responsible for ensuring that all grease. Under normal operating conditions the fill should
maintenance inspection and installation work is carried out be replenished every 1500 hours by an injection roughly
by authorized, duly qualified staff who are thoroughly equal to one half of the amount originally used to pack the
familiar with these operating instructions. bearings. After 20000 operating hours or 2.5 years the
bearings should be checked, then cleaned and re-
A regular maintenance schedule will help avoid expensive lubricated if required.
repairs and contribute to trouble-free, reliable operation of
the pump with a minimum of maintenance expenditure.
For this purpose use high-quality lithium-soap grease, free
Work on the unit must only be carried out with of resin and acid, not liable to crumble and with good rust-
the electrical connections disconnected and preventive characteristics. The type of grease required for
locked out. Make sure that the pump set cannot be temperatures above 0 degrees Fahrenheit is Chevron
switched on accidentally. Ultra-Duty Grease 2 (Lithium Base) or equivalent. For
temperatures below 0 degrees Fahrenheit, use Chevron
Pumps handling liquids posing health hazards
must be decontaminated. When draining the Avi-Motive Grease W or equivalent. The bearing cavities
medium ensure there is no risk to persons or the should be fully packed with grease.
environment. All relevant laws must be adhered to.
Approximate Grease Capacity
7.2 Maintenance / Inspection Bearing Spherical Taper
7.2.1 Supervision of Operation Assembly Roller Bearing Roller Bearing
The pump should run quietly and free from ml (oz) ml (oz)
Caution
vibrations at all times. Unusual noise or 35mm 15 (0.5) 20 (0.7)
vibration should be investigated and corrected 50mm 20 (0.7) 40 (1.4)
immediately. 70mm 30 (1.0) 90 (3.0)
100mm 90 (3.0) 190 (6.4)
Operational procedures that may cause system 125mm 140 (4.7) 280 (9.5)
water hammer must be avoided. Sudden and
catastrophic failure of pump casing and plates may
After adding grease, some excess may be expelled from
result.
the labyrinth oil seals. This is normal and will stop once
the excess grease has been purged.
When running the pump against a closed discharge-side
shut-off element for a short period, the permissible
7.2.2.3 Oil Changes
pressure and temperature values must not be exceeded.
The first oil change should be carried out after 300
operating hours, the following ones after every 3000 hours
Prolonged operation against a closed shut-off
or when it appears or is suspected of being dirty or
element is not permitted. Danger of steam
contaminated.
generation and explosion!
See section 6.1.1 for oil specifications and capacities.
Verify correct oil level as described in Section 6.1.1.

14
 LCC
When lifting a plate that contains two swivel hoist
7.3 Drainage / Disposal rings, do not allow the angle between the lines of
If the pump was used for handling liquids tension from the rings exceed 120°. This could cause the
Caution
posing health hazards, see to it that there hoist rings to fail.
is no risk to persons or the environment when draining the
medium. All relevant laws, local codes, and safety Impeller Break-Loose Jig
procedures must be heeded. If required, wear safety Rotate the impeller until the tip of one blade is facing the
clothing and a protective mask. pump discharge. Insert the jig through the eye of the
impeller and attach to trailing edge of blade facing
If the media handled by the pumps leaves residues which discharge. Rotate the shaft in the direction opposite to
might lead to corrosion when coming into contact with normal, using the pump pulley or a spanner wrench.
atmospheric humidity, or which might ignite when coming
into contact with oxygen, the unit must be flushed NOTE: For ease of impeller removal, the shaft threads
thoroughly and neutralized. should be heavily coated with anti-seize compound during
re-assembly. Also, two aramid paper gaskets should be
The flushing liquid used and any liquid residues in the used between the shaft sleeve and the impeller.
pump must be properly collected and disposed of without
posing any risk to persons or the environment. BREAK LOOSE JIG

7.4 Dismantling IMPELLER

Before dismantling, secure the pump so as to make
sure it cannot be switched on accidentally. The
shut-off elements in the suction and discharge nozzles
must be closed. The pump must have cooled down to
ambient temperature, it must be drained and its pressure
must be released. Observe the safety regulations of
Section 7.1.

Repair and maintenance work to the pump must only be

carried out by specially trained personnel, using original
equipment spare parts (see 2.7)

7.4.1 Sectional Drawings and Bills of Material

The manual you are reading is a basic manual for all
LCC type pumps. For sectional drawings and bills of Figure 7.4-1 Impeller Break-Loose Jig
material relating to your specific pump and
equipment, locate an official copy of the Impeller Lifting Jig
documentation provided by GIW / KSB. This may be For impeller removal or installation, grasp the impeller at
shipped separately from the pump and will include the suction eye as shown in Figure 7.4-2. The impeller can
drawings and bills of material as attachments to this be leveled by turning the adjusting bolt which bears
basic manual. against the impeller nose. This is especially useful during
re-installation. For impeller removal ensure that the lifting
Dismantling and reassembly must always be carried out in line is tight prior to thread disengagement.
accordance with the relevant sectional drawing. Any work
on the motor, gear reducer, mechanical seal or other non- Do not remove, lift, move or re-install impeller
pump equipment shall be governed by the specifications without properly using a recommended impeller
and regulations of the respective supplier. lifting jig.

7.4.2 Dismantling Procedures Impeller

During normal operation, the impeller becomes tightly
screwed onto the shaft by the running torque. A steady
torque or mild, yet sudden, torsional jolt is usually required
to disengage the impeller. Several methods of achieving
this end are possible. One of the easiest methods is
outlined below. To order the jigs described here, contact
your GIW / KSB representative. Please provide your pump
assembly number with the order to insure a good fit.

Do not apply heat to the impeller hub or nose

due to the sealed cavity at the impeller nose.
DANGER OF EXPLOSION!

For Plates Using Swivel Hoist Rings

Always ensure that lifting equipment does not bind
to the hoist ring. Binding can cause ring failure.

15
 LCC
Removing the Expeller
Before removing the expeller, ensure that the 2 bolts in the
3 & 9 o’clock positions (901.13) that secure the expeller
casing (10-7) to the pump pedestal have not been
removed. See Figure 4-3.5.

For 2x3 and 3x4 LCC-M, use two of the holes left open
and two spare bolts, (not included), to secure the expeller
casing (10-7) to the pump pedestal.

If not secured in the above manner, the expeller

casing may fall without warning after the expeller is
removed.

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

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

Figure 7.4-2 Impeller Lifting Jig Cartridge Bearing Assembly

Drain the oil (if applicable) by removing the drain plug on
Shell the bottom of the housing.
It is recommended that at least two lift points be used
when moving any pump shell. This permits greater safety Remove the flingers (if any) and bearing housing end
and control of the component. Where applicable, GIW covers. Care should be taken with the Inpro oil seals,
pump shells are supplied with cast lifting eyes for this which should not be removed from the end covers unless
purpose. Note that if the chain hook does not fit the lifting they have been damaged and are in need of replacement.
eye, an appropriate clevis should be installed. Another Inspect the seals, gaskets, and o-rings, and discard any
acceptable lifting point is a chain secured around the that appear worn or broken.
discharge flange, being careful not to damage the bolt
flanges. The locknut and lock washer that clamp the drive side
bearing should also be removed. One tab of the lock
Elastomer-Lined Wet End washer will be bent into a recess on the lock ring and must
Most liners fit snug into the casings. Two threaded push- be bent back to allow the lock nut to be unscrewed.
off holes at 180 degrees are provided in the casings to aid
in removal. If reuse of the liners is anticipated, care must The shaft and bearings (which are pressed onto the shaft)
be taken to push the liners out evenly to avoid bending of may then be removed as a unit from the drive end of the
the steel backing plate. housing. Horizontal disassembly is acceptable when
proper support is given to the shaft to prevent its
Expeller Assembly: contacting and marring any of the finished surfaces of the
- for 2x3 and 3x4 LCC-M Pumps shaft or bearing housing bore. Care should be taken to
After supporting the pump shell, remove the nuts from all avoid damaging the grease retaining ring (part 63-7,
four of the studs (902.10) which hold the shell in place. grease lubricated) or spacer ring (part 45-4, oil lubricated)
that will come out on the shaft between the two bearings.
Dismount the shell and the expeller plate (16-4) together,
allowing the expeller casing to rest on and be supported The bearings are hot when installed on the shaft, and fit
by the 4 studs. tight. It is difficult to remove them from the shaft
undamaged, and they should be removed only if a bearing
Go to the “removing expeller” section below. needs to be replaced. Bearings are normally removed by
heating, which should be done quickly to prevent heating
- for LCC-R, LCC-H, and all other LCC-M Pumps of the shaft as well. Flame cutting of the outer race and
After supporting the pump shell, remove the nuts from all careful grinding of the inner race may occasionally be
six of the studs (902.10), which hold the shell in place. required; however, care must be taken to avoid damaging
This excludes hex head bolts at the 3 & 9 o’clock positions the shaft, especially in the oil seal area.
which mount the expeller plate to the shell (901.14) and
expeller casing to the pedestal (901.13). Dismount the 7.5 Reassembly
shell and the expeller plate (16-4) together. 7.5.1 General Instructions
The pump should be reassembled in accordance with the
If not removed in the above manner, the expeller rules of sound engineering practice. Use the sectional
plate may fall without warning after the shell is drawing and bill of material for guidance.
removed.
See section 7.4.2 for safety precautions regarding lifting
plates with swivel hoist rings.

16
 LCC
Before assembly, thoroughly clean all
Caution
shaft, housing bore, and end cover
surfaces with a suitable solvent to remove old grease and
any water, dust or grit. Clean all dismantled components
and check them for signs of wear. Damaged or worn
components are to be replaced by original equipment
spare parts. Make sure that the seal faces are clean and
the O-rings and gaskets are properly fitted.
7.5-1 Back to Back Taper Roller Bearing
It is recommended that new seal elements (O-rings/
gaskets) be used whenever the pump is reassembled.
Make sure that new gaskets have the same thickness as
the old ones. Avoid the use of mounting aids as much as
possible. Should a mounting aid be required, use a
commercially available contact adhesive. The adhesive
should only be applied at selected points (three to four
spots) and in thin layers. Do not use cyanoacryiate
adhesives (quick-setting adhesives). If in certain cases 7.5-2 Face to Face Taper Roller Bearing
mounting aids or anti-adhesives other than those
described are required, please contact the sealing material 7.5.3.1 Back to Back Thrust Bearing Installation
manufacturer. (See section 7.5.3.2 for face to face)
7.5.2 Mounting Radial Bearing Cup
o o
Heat radial bearing to 120 C (250 F) by a suitable
bearing heater, oil bath, or other even heating device prior
to mounting. Flame heating is not recommended.

Inboard
Outboard Side
Side
Cone / Roller

Spacer
Figure 7.5-5
Figure 7.5-3
For oil: Install spacer ring 45-4 and ensure proper
Install radial bearing onto shaft. Figure 7.5-4 orientation.

For grease: Install grease retaining ring 63-7 and ensure

proper orientation. See figure 7.5-6

Figure 7.5-4
Figure 7.5-6 (Grease)
Press fit bearing ensuring that it is seated fully against the
abutting shaft shoulder.
The grease retaining ring (63-7, for grease
Caution
lubrication) or spacer ring (45-4, for oil
7.5.3 Mounting Thrust Bearing
lubrication) must be placed on the shaft between the
Caution Before getting started, use the bearing
bearings, and in the proper orientation, before both
assembly drawing to determine if the
bearings are mounted. Once the bearings are mounted,
bearing assembly uses the face to face or back to back
they cannot be removed without risk of damage. The
taper bearing arrangement.
grease ring is essential in protecting the taper bearing
from loss of lubrication in the event of high loadings.
Failure to install the ring may result in significantly reduced
bearing life.

17
 LCC
o
Heat inboard cone (250 F) and install. Ensure that the Before the taper roller bearing has cooled on the shaft,
larger OD of the bearing is towards the center of the shaft. use the lock nut without lock washer to fully seat the
Figure 7.5-7 bearing against the shaft shoulder. (The lock washer must
be left out during this step to prevent damage) Figure
7.5-11

Figure 7.5-7

Install spacer. Figure 7.5-8

Figure 7.5.11

After the bearings have cooled, remove the locknut and

reinstall with lock washer against the taper roller bearing,
tightening the nut according to the torque given in Section
7.5.15.

Over-tightening can damage the lock

Caution
washer and allow the locknut to back off
during operation.

Do not back off the locknut any amount

Caution
Figure 7.5-8 after tightening in an attempt to set the
bearing clearances. The LCC taper bearing has an
Install bearing cup. Figure 7.5-9 internal spacer, which automatically sets the internal
bearing clearances.

After tightening, bend down one tab of the lock washer

into one of the mating grooves on the locknut. If none of
the tabs are aligned with a groove, locate the nearest one,
and further tighten the locknut until the tab can be bent
down.

Failure to bend down one of the lock washer tabs may

allow the locknut to back-off and lead to premature
bearing failure.

Ensure that the bearing outer diameters and housing

Figure 7.5-9 bores are clean. Coat shaft between the bearings with
GIW Blue Synthetic Bearing Lubricant.
A clip may be used to hold the cup in place. Figure 7.5-10
Lift shaft vertically and place into housing from drive end.
Figure 7.5-12. It will be necessary to align the grease ring
63-7 or spacer 45-4 as it enters the housing since it has
about 6mm (0.25 in.) of clearance with the shaft.

The bearings should slide easily and fully

Caution
into the bearing housing without excessive
force that would indicate possible dust or grit between the
bearings and the housing, and result in a thrust preloading
on the impeller end spherical roller bearing. Preloading of
the bearing will cause it to carry thrust loadings, which
would normally be carried by the taper roller bearing and
can result in overheating and premature failure of the
Figure 7.5.10 spherical roller bearing.
o
Heat the outboard cone to (250 F) and install. Ensure that
the larger OD of the bearing is towards the drive end of
the shaft.

18
 LCC

Figure 7.5-16

After both cones are installed and before the taper roller
Figure 7.5-12 bearing has cooled on the shaft, use the lock nut without
lock washer to fully seat the bearing against the shaft
Skip to section 7.5.4 shoulder. (The lock washer must be left out during this
step to prevent damage)
7.5.3.2 Face to Face Thrust Bearing Installation
(See section 7.5.3.1 for back to back) After the bearings have cooled, remove the locknut and
reinstall with lock washer against the taper roller bearing,
Spacer
tightening the nut according to the torque given in Section
7.5.15.

Over-tightening can damage the lock

Caution
washer and allow the locknut to back off
Inboard
during operation.
Outboard Side
Side Do not back off the locknut any amount
Cup Caution
after tightening in an attempt to set the
bearing clearances. The LCC taper bearing has an
Cone / Roller internal spacer, which automatically sets the internal
Figure 7.5-13
bearing clearances.
Place the cup of the inboard bearing onto the shaft. Figure
After tightening, bend down one tab of the lock washer
7.5-14
into one of the mating grooves on the locknut. If none of
the tabs are aligned with a groove, locate the nearest one,
and further tighten the locknut until the tab can be bent
down.

Failure to bend down one of the lock washer tabs may

allow the locknut to back-off and lead to premature
bearing failure.

Ensure that the bearing outer diameters and housing

bores are clean. Coat shaft between the bearings with
GIW Blue Synthetic Bearing Lubricant then lift shaft
vertically and place into housing from drive end. Figure
Figure 7.5-14 7.5-17.

Heat the inboard cone to120°C (250°F) and press fit onto The bearings should slide easily and fully
Caution
the shaft. Figure 7.5-15. into the bearing housing without excessive
force that would indicate possible dust or grit between the
bearings and the housing, and result in a thrust preloading
on the impeller end spherical roller bearing. Preloading of
the bearing will cause it to carry thrust loadings, which
would normally be carried by the taper roller bearing and
can result in overheating and premature failure of the
spherical roller bearing.

Figure 7.5-15

Heat the outboard bearing cone to 120°C (250°F) and

press fit onto the shaft. Figure 7.5-16

19
 LCC
portion of the outer diameter o-ring, however, this is
normal and indicates a secure fit.

Bottom

Figure 7.5-20

Slide end covers with gaskets and Inpro seals over the
shaft at each end, again making certain that the
contaminant expulsion port and lubrication return trough
Figure 7.5-17
are located at the bottom. Use O-Ring lubricant, Parker O-
Lube or Parker Super-O-Lube to lubricate the inner
Insert the spacer and cup for the outboard bearing using a
diameter o-rings against the shaft. Take special care when
rubber mallet. Figures 7.5-18& 7.5-19
running the seal over the shaft keyway to avoid cutting the
o-ring. If necessary, lightly file the keyway edges to avoid
this problem.

After bolting the end covers in place, rotate the shaft by

hand. There should be no frictional contact between the
rotating and stationary parts of the Inpro seal. Any rubbing
or axial movement in the seal may indicate misalignment.
If this is the case, tap lightly into alignment.

Note that the drive side end cover clamps against the
outer race of the taper roller bearing and may not fit flush
against the housing. No shimming is necessary. A gap of
up to 1mm (0.04 in.) is acceptable and within the tolerance
Figure 7.5-18 of the parts. Any larger gap may indicate that the taper
roller bearing is not fully seated into the housing.

Install grease fittings or oil plugs

See Section 7.2.2.2 for grease lubrication requirements.

See Section 6.1.1 for oil lubrication requirements.

Figure 7.5-19

7.5.4 Installing End Covers and Seals

The standard bearing housing shaft seal is the Inpro VBX
type labyrinth seal. Other seal types may be available
including the Caterpillar Duo-Cone seal for underwater
bearing assemblies. See your arrangement drawing for
specific information regarding these alternate seal types.

Prior to installation, press the Inpro shaft seals into each

end cover, ensuring that the contaminant expulsion port
and lubrication return trough are located at the 6 o’clock
(bottom) position. Figure 7.5-20. If possible, use a hand
operated arbor press instead of a hydraulic press to
Figure 7.5-21 VBX Inpro Seal for LCC
improve control of the pressing operation. You will be
overcoming a light interference fit and may shear off a

20
 LCC
7.5.5 Mounting Shaft Sleeve when needed. When the water purge port is not utilized, a
In mounting the shaft sleeve, do not allow anti-seize pipe plug should be used to seal the port opening.
compound to come in contact with any of the axial faces
of the shaft sleeve, including the impeller contacting face 7.5.7 Mounting the Bearing Assembly to Pedestal
or the face in contact with the shaft shoulder. For ease of After mounting the stuffing box (or mechanical seal
removal, a light coating of anti-seize compound should be adapter) loosely onto the pedestal plate, and screwing the
applied to the inner diameter of the shaft sleeve. adjusting screw (909) with nut (924) an appropriate length
into the pedestal, the cartridge bearing assembly may be
Lubrication at any of shaft sleeve or shaft shoulder placed onto the pedestal saddle. Note that the slotted tab
faces may result in overloading and breakage of the on the housing must be inserted between the adjusting
shaft. screw shoulder and the adjusting nut.

In many cases, there will be an o-ring which must be The pedestal and bearing housing saddles should be
placed on the shaft first. As the shaft sleeve is pushed into clean, dry, and free from oil or grease. If corrosion of the
position, this o-ring should be completely forced into the saddles is a problem, apply a thin film of preservative.
shaft sleeve recess. Special care must then be taken in the axial adjustment
procedure to ensure that no movement may occur. (See
If a non-split lantern ring or throat bushing is being used, it the section on Axial Adjustment of Bearing Housing.)
should be placed onto the shaft sleeve at this time.
The four bearing housing hold down clamps (732) may
now be bolted on, but should remain slightly loose until the
axial adjustment of the bearing housing is complete.

7.5.8 Metal Expeller Assembly

- for 2x3 and 3x4 LCC-M Pumps
Mounting the expeller casing (10-7) to the pedestal using
two spare bolts (not provided) at 180 degrees to each
other to hold it temporarily in place.

Figure 7.5-22 Standard LCC Shaft Sleeve Arrangement Before mounting the expeller (23-15) a 0.5 mm (0.020
inch) aramid gasket (400.31) is placed between the shaft
7.5.6 Mounting Stuffing Box sleeve and the expeller to prevent galling and ensure ease
7.5.6.1 Stuffing Box of removal. The gasket should be installed dry, without
The stuffing box should be mounted so that the sealing grease.
water tap is on or near the vertical centerline. This will
position the gland studs at 9 o’clock and 3 o’clock for easy After mounting the expeller, which is a close sliding fit to
access. Note that the small stuffing boxes have a single the shaft, adjust the bearing assembly towards the drive
inlet while the larger sizes have a second port that can be end until the expeller just begins to rub on the expeller
used for additional flow or have a pipe plug installed. casing. Then move it back towards the pump end approx.
1.0 mm (0.4 inch). This is a preliminary adjustment. Final
Location of the stuffing box is provided by a close adjustment will be made after wet end assembly is
clearance fit with the pedestal. No additional centering complete.
operation is required.
Mount the expeller plate (16-4) at the same time the shell
In some cases, a separate stuffing box wear plate may be or casing is mounted by inserting the studs into the shell
provided. Apply RTV to the back of the wear plate before or casing and allowing the expeller plate to rest on and be
bolting it to the stuffing box. supported by the studs.

See Figure 4.3-4 for typical stuffing box arrangement. If attempt is made to mount the expeller plate
without the support of the shell or casing studs, it
7.5.6.2 Packing (non-expeller) will not be properly supported and may fall without warning.
The packing arrangement consists of a lead ring, followed
by a standard lantern ring, and then three more rings of See Figure 4.3-5 for typical expeller arrangement.
packing (two rings for 70mm shaft).The packing should be
well coated with water resistant grease during assembly. - for LCC-R, LCC-H, and all other LCC-M Pumps
See figure 4.3-4. Mount the expeller casing (10-7) to the pedestal using two
hex head bolts (901.13) at the 3 & 9 o’clock positions with
7.5.6.3 Packing (expeller) the bolt heads on the expeller casing side.
As of 2004, the static seal for the expeller has been
modified. The forward ring of packing and the standard Before mounting the expeller (23-15) a 0.5 mm (0.020
lantern ring have been replaced with a low flow throat inch) aramid gasket (400.31) is placed between the shaft
bushing. The throat bushing is followed by a ring of sleeve and the expeller to prevent galling and ensure ease
packing, a special lantern ring, and then a second ring of of removal. The gasket should be installed dry, without
packing. All rings of packing should be well coated with grease.
water resistant grease during assembly. See figure 4.3-5
After mounting the expeller, which is a close sliding fit to
There is an additional rear tap on the stuffing box for the shaft, adjust the bearing assembly towards the drive
grease lubrication of the packing, allowing the primary end until the expeller just begins to rub on the expeller
(forward) taps to be reserved for intermittent flush water, casing. Then move it back towards the pump end approx.
21
 LCC
1.0 mm (0.4 inch). This is a preliminary adjustment. Final 7.5.11 Impeller
adjustment will be made after wet end assembly is Coat the shaft threads heavily with anti-seize compound.
complete. Do not coat the shaft sleeve faces which contact the
impeller and the step in the shaft.
Mount the expeller plate (16-4) to the shell using two hex
head bolts (901.14) at the 3 & 9 o’clock positions. Mount Two 0.5mm (0.020 inch) aramid gaskets (400.10) are
the expeller plate and shell to the expeller casing and placed between the shaft sleeve and the impeller hub face
pedestal by inserting studs into the remaining stud to prevent galling and to ensure ease of impeller removal.
positions. Hex head bolts at the 3 & 9 o’clock positions The gaskets should be installed dry, without grease.
should not be removed or replaced with studs.
Screw on the impeller tightly by hand. With larger sizes, it
If attempt is made to mount the expeller plate may be convenient to hold the impeller stationary while
without the support of the shell or casing studs, it turning the shaft. Impeller lifting jigs are available to assist
will not be properly supported and may fall without warning. in this operation (see Figure 7.4-2).

See Figure 4.3-5 for typical expeller arrangement. When assembly of the pump is complete, check the
impeller to suction wear plate clearance and adjust if
7.5.9 Mounting Shell necessary, (see section on Axial Adjustment of Bearing
The alignment of the pump shell with the mechanical end Housing).
is obtained through a rabbet fit machined into the
pedestal. For the best wear and efficiency performance, it 7.5.12 Suction Plate and Liner (LCC-H only)
is essential that the shell be fully seated in this fit. Bolt the suction liner to the suction plate and install o-ring
before mounting to shell.
Ensure that the proper gasket is fitted between the shell
and pedestal before installing. After mounting, the suction liner should protrude
In the case of the elastomer lined LCC-R pump, the liner approximately 1.0 mm (0.04 inch) from the suction plate at
itself forms the seal. See below for additional instructions. the suction flange connection. This is normal and provides
the sealing surface for the suction piping. It is important
7.5.10 Elastomer Lined Wet End that excessive force is not placed on the liner by using a
Firmly seat the liners into the metal casings using a large raised face flange or a gasket that covers the liner
rubber mallet if necessary. To seat the suction side liner, protrusion only. In general it is recommended that a full
use a wooden brace and large C-clamps, or lay the liner, face flange and full face gasket is used to connect the
flange side up, on a wooden brace and lower the metal suction piping.
casing onto it, allowing the weight of the casing to seat the
liner. Seat the elastomer flanges into their grooves using a
blunt tool if necessary.

The close fit of the liners, although requiring some effort in

assembly, will ultimately ensure better liner support, and
longer wear life. If desired, liquid soap may be used to
lubricate the liners during assembly.

Do not use petroleum-based products

Caution
to lubricate the liners since they can 7.5.13 Axial Adjustment of the Bearing Housing
cause degradation of the elastomer. In order to maximize the performance and reduce wear,
the clearance between the suction face of the impeller and
Before assembling the casing halves together, check the the suction liner must be adjusted to a minimum clearance
fit of the liners in the casing to ensure that they are seated of 0.25 mm (0.010 in.). This is done by moving the bearing
correctly, especially in the suction, hub, and discharge housing assembly with the adjusting screw.
flange areas. Clearance allowing for limited readjustment
of parts has been provided in the holes through which the Before adjustment may proceed, the pump wet end must
liner studs protrude. be completely assembled. The stuffing box may be
packed before or after the adjustment procedure;
When bolting the casings together, ensure that the liners however, the axial set of any mechanical seal must be left
remain well aligned with each other on their outer until after adjustment is complete.
perimeter, especially in the discharge area. Some bulge
may occur at the seam on the discharge flange. This may After insuring that the four bearing housing clamps are
be removed, and the sealing surface restored to flatness slightly loosened, run the bearing assembly towards the
by lightly buffing with a coarse grade sand paper or impeller end by means of the adjusting screw until the
grinding stone. If desired, rubber gaskets may be applied impeller first begins to rub the suction liner. It is helpful to
at both the suction and discharge flanges, although this is slowly rotate the impeller during this procedure.
typically not necessary.
Next, reverse the adjusting screw until the clearance
Some bulging may also occur inside the casing between between the impeller and the suction liner is brought to the
liners. This is normal and does not affect performance. recommended value shown in the table below.

22
 LCC
gauge to come closer than 1.0 mm (0.04 in.) to the original
Impeller Nose Clearance zero setting or expeller rubbing may occur. If necessary,
Shaft Size consider the use of a spacer as mentioned in step 4.
inch (mm)
All Sizes 0.010 (0.25)
7.5.15 Tightening Torques
Taper Bearing Locknut Assembly Torque
Once the clearance is correct, lightly tighten the bolts of
the four bearing housing clamps by hand, making sure Locknut Assembly Torque
Bearing Assembly
that proper contact is maintained at all four locations. Next N-m ft-lbs
fully tighten the bolts according to the requirements of 35 mm 100 75
Section 7.5.15. Finally, firmly lock the adjusting screw and 50 mm 135 100
nut together against the bearing housing tab. 70 mm 200 150
100 mm 375 275
Proper tightening of the bearing housing 125 mm 680 500
Caution
clamps and adjusting nut is essential to
prevent movement of the rotating assembly during Bearing Assembly Clamp Bolts
operation. Failure to do so can result in severe vibration
and damage to all pump components. Bearing Clamp Bolt Torque
Bolt Size
Assembly N-m ft-lbs
7.5.14 Expeller Running Clearance 35 mm
M20 340 250
Proper adjustment of the impeller nose clearance as 50 mm
covered in the section Axial Adjustment of the Bearing 70 mm
Housing should result in proper expeller clearances in the 100 mm M24 680 500
new condition and no further adjustments should be 125 mm
necessary.
1) LCC pumps built prior to 1998 may use clamping bolts
In some cases adjusting the impeller after excessive one size smaller than shown above. If your unit is of this
suction liner wear may result in the expeller rubbing type, reduce the torque values as follows:
against the expeller plate. In other cases it is desired to 35,50mm with M16 bolt: 270 N-m (200 ft-lbs)
optimize expeller performance rather than optimize the 70,100,125mm with M20 bolt: 340 N-m (250 ft-lbs)
impeller clearance.
Other Bolts
The following procedure is recommended for optimizing No special torque requirements exist for the remaining
expeller performance or for setting the clearances in LCC nuts and bolts unless specifically called for on the
pumps containing any worn parts: assembly drawing. Bolts and nuts for which torque is not
specified should be tightened enough to ensure a firm
1 With the suction plate/liner removed, adjust the mating between parts in accordance with good
bearing assembly toward the pump end until the back maintenance practice. Where possible, the use of an air
surface of the expeller just begins to rub the expeller plate. driven impact wrench is recommended for bolts over
24mm (1.0 inch) diameter.
2 Mount a dial gauge to indicate cartridge bearing
assembly axial movement and zero the dial gauge at this For additional torque values see section 9.0
location.
7.5.16 Water Purge for Gland Packing
3 Now adjust the bearing assembly toward the drive (or The stuffing box is equipped with tapped holes for sealing
motor) end until the expeller vanes just begin to rub on the water. In order to keep the stuffing box free from abrasive
expeller casing, or the impeller begins to rub on the hub particles, the sealing water pressure and gland (452)
side of the pump shell, whichever comes first. tightness should be adjusted to maintain a small flow of
cool or lukewarm leakage out of the stuffing box. If the
4 Adjust the bearing assembly toward the pump end leakage becomes hot, the gland should be loosened to
again approximately 1.0 mm (0.04 in.) to provide a allow a greater flow. If cloudiness is seen in the leakage,
minimal expeller running clearance. If optimization of greater water pressure is needed.
expeller performance is desired, lock the adjustment at
this location Purge water must be non-aggressive, not liable to form
deposits and not containing suspended solids.
Optimizing the expeller clearances is (Hardness: on average 5; pH > 8, or conditioned and
Caution neutral with regard to mechanical corrosion).
recommended only in cases where
expeller performance is marginal and a small increment in Inlet temperature tE = 10 to 30o C (50 to 85 o F)
o o
performance is required to seal against the pump Outlet temperature tA max. 45 C (115 F)
pressure. Setting of clearances for optimal expeller The sealing water pressure required to maintain
performance may result in excessive impeller clearance satisfactory stuffing box operation will vary with pump
and accelerated wear. If necessary, this may be remedied operating pressure, slurry properties, condition of the
by providing a custom fitted machined spacer with gaskets packing, and the type of stuffing box. A supply pressure of
between the impeller and expeller. 10 psi (0.7 bar) over the discharge pressure of the pump
should be available. In most cases, adjustments to supply
5 Reassemble the suction plate and check the impeller pressures can be made with a manual valve and gauge
to liner clearance. If not optimizing expeller clearances set near the stuffing box.
the impeller clearance as detailed in the section “Axial
Adjustment of the Bearing Housing”. Do not allow the dial

23
 LCC
Flow Control Option
The KE stuffing box is a Low Flow design and must be 7.6 Spare Parts Stock
pressure controlled. Flow control can result in burning or Due to the erosive action of the slurry, many of the wet
jamming the packing. Actual flow in a properly maintained end components of the pump may require replacement
and adjusted stuffing box is considerably less than shown during normal maintenance. Inspection or overhaul of the
in the Table. mechanical components may also warrant replacement of
certain parts.
Forward Flush and Throat Bushing stuffing boxes are
generally pressure controlled, but flow control is an option. The following are recommended lists of parts to have on
Seal water requirements listed in the table show potential hand for normal maintenance and inspection. The
flow with worn packing. quantities of parts kept in store will depend upon the
severity of the slurry duty and the number of units
Flow control may be achieved in different ways. A Positive operating. Maintenance practices may also favor keeping
Displacement pump that delivers the correct volume can fully built sub-assemblies or complete pumps on hand in
be used with a safety or “pop-off” valve so the purge some cases. Previous experience in similar duties often
pressure can never exceed 10 psi (0.7bar) above the provides the best experience. If in doubt, contact your
Maximum Working Pressure of the pump. Where water GIW / KSB representative for specific recommendations.
supply is adequate, install a flow meter and regulating
valves in the line. A backflow preventer is recommended Wet End Stuffing Box
to prevent reverse flow should the pump pressure exceed • Casing (or casing liners) • Shaft Sleeve
supply pressure. All components must have adequate • Impeller • Seal Water Ring
pressure ratings. Verify that components will work with the • Side Liner • Packing
volume, pressure and water quality supplied to the stuffing • Gasket Kit • Gasket Kit
box.
Bearing Assembly Expeller
For best performance each pump should be adjusted for • Bearings • Casing
minimum water consumption while still providing adequate • Gasket Kit • Plate
drip rate. As the volume of water is reduced, the stuffing • Expeller
box gland will need to be loosened slightly to maintain the • Gasket Kit
proper drip rate. This will ensure adequate flush while
limiting water use. The temperature of the water exiting 7.6.1 Maintenance Procedures for Maximum Parts
the stuffing box can be a better indicator than “drip rate” or Life
volume. This should be at a temperature that would be The wear of slurry pump parts is influenced by many
comfortable for hand washing which indicates that the factors and the following procedures are designed to help
packing is not overheated. you get the most out of your wet end wear parts. If
problems occur, contact your GIW / KSB representative
Stuffing Box Maximum Seal Water Requirements for a review of your application.
For hot, high pressure or otherwise severe service
conditions, an optional combination lantern ring / throat Also see section 7.7: “Operational Problems and
bushing is recommended in place of the standard lantern Solutions”.
ring and first ring of packing. Water requirements for this
option will be about mid-way between the forward flush Suction Liner
and KE configurations shown in the table below. The suction liner should be rotated 180° at approximately
half-life if localized wear occurs. If localized wear is
Stuffing Box Type severe, repair as recommended by GIW / KSB before
Shaft Standard Throat rotation.
Forward Flush
Size KE (Non-Standard) Bushing
A new gasket should always be used with a new suction
l/sec (gpm) l/sec (gpm) l/sec (gpm)
liner or new shell.
35mm 0.09 (1.4) 0.44 (7.0) 0.18 (2.8)
Impeller
The impeller to suction liner clearance should be adjusted
50mm 0.11 (1.7) 0.54 (8.5) 0.21 (3.4)
forward several times during its life cycle for maximum
impeller and suction liner life. See section 7.5.13.
70mm 0.15 (2.4) 0.76 (12.0) 0.30 (4.8)
In general, an impeller does not require replacement until
100mm 0.20 (3.1) 0.98 (15.5) 0.39 (6.2) it fails to produce sufficient head for the application.
Impellers are sometimes changed too soon based on
appearance. Vibration caused by an impeller wearing out
125mm 0.23 (3.7) 1.17 (18.5) 0.47 (7.4) of balance is rare but possible. If this occurs, the impeller
may be statically balanced by hand grinding on back
For expeller applications, the stuffing box used must be of shroud.
the ‘KE’ (low flow) type with a ring of packing between the
lantern ring and pumped fluid. All rings of packing should The impeller should never be repaired by welding.
be well coated with water resistant grease during
assembly. Shell
If wear is localized with a deep gouge, repair or replace as
recommended by GIW / KSB. Excessive wear problems
are usually indications that the pump is not operating at
24
 LCC
the flow and head conditions originally specified for the
design. Piping diameters must be properly sized to maintain
sufficient carrying velocity. Oversized pipelines may result
7.7 Operational Problems and Solutions in the formation of a sliding bed of slurry, which can
Many pump wear problems are caused by unstable greatly accelerate the wear of pumps and pipelines.
system operation, or off duty pump operation. Although
the dynamics of slurry piping systems cannot be fully Operating Conditions of Flow and Head
addressed in this manual, the following items should be It should be noted that the pump always operates at the
considered. Also refer to section 8: “Trouble Shooting” intersection of the pump curve and the pipeline "system"
curve.
Sump Design
A minimum sump capacity of one minute at the expected During the initial stages of operation, motor load on the
flow conditions should be provided. Sump design should pump should be checked. If there is an excess amount of
prevent any uneven flow of the solids to the suction. Often, power being drawn by the pump, it may be caused by the
a flat bottom sump is best since it will allow the solids to system head (TDH) being lower than predicted thus
assume a natural slope of repose. The sump should be resulting in higher flow rates and power consumption. This
observed during operation to insure that solids are not sometimes happens when a safety factor is applied to the
building up and sloughing off. head during the design of the system. Cavitation may also
occur under these high flow conditions. The pump speed
Sump design should prevent the formation of a vortex, or should be slowed down to reduce flow, or the total
other means of introducing air into the pump. Where a discharge head against the pump should be increased
submerged suction is available, the depth of water level (resulting in reduced flow and power consumption).
above the pump suction is more important than the cross-
sectional area of the sump. Frothing of the sump should If actual supply flow rates are lower than predicted, the
be eliminated by the installation of baffles, a submerged sump may run dry causing the system to surge and
inlet pipe or other methods to prevent air becoming accelerating pump wear. Pump speed or impeller diameter
entrained in the slurry. If unavoidable, frothing must be should be decreased or make up water increased to keep
accounted for in the system design and operation. the sump at the highest stable level possible. If the flow
variations are too great, a variable speed motor may be
If the sump runs dry, the system will surge causing required. This problem is especially common in
accelerated pump wear. Pump speed or impeller diameter applications with a high proportion of static head, such as
should be decreased or make up water increased. If the mill discharge and cyclone feed. It can be further
flow variations are too great, a variable speed motor may aggravated by operation well below the best efficiency
be required. flow rate of the pump where the pump head curve is
relatively flat. Under these conditions, minor fluctuations in
Cavitation / NPSH Performance the system resistance caused by normal variations in
The NPSH available must always be greater than the solids concentration or size can result in surging flow
NPSH required by the pump or cavitation will occur rates.
resulting in head loss (drop in discharge pressure),
increased wear rate of the pump parts, and shock loading Whenever possible, avoid prolonged operation at flows
of the pump bearing assembly. If any conditions occur, well below the optimum flow rate. This causes
consult your GIW / KSB representative for the NPSH recirculation of slurry within the pump and encourages
requirements of your pump. localized wear.
In the event problems are encountered, contact your GIW
To maximize the NPSH available to the pump, insure that / KSB representative. The pump serial number, in addition
the suction line is as short and straight as possible and the to the following, should be furnished to assist in evaluation
sump level is as high as possible, (or the suction lift as of the problem:
small as possible in the case of a pump located above the
water level). Minimizing the number of valves or short A. Pump serial number (from the nameplate on the
radius fittings and attaching a suction inlet bell will also pedestal), customer location, and the approximate
reduce entrance losses. A larger diameter suction pipe startup date.
may help, but one must be careful not to reduce the flow
velocity below safe carrying levels or bedding of the slurry B. Pumped fluid SG (specific gravity), slurry information
will occur and result in increased suction liner and impeller including SG and particle size, and liquid temperature.
wear.
C. The approximate flow rate desired and the actual
In dredging applications where a free suction pipe or minimum and maximum flow rate of the system if
suction cutter head is lowered into the solids to be known.
pumped, it is useful to have pressure gauges attached to
the pump suction and discharge. An operator, by D. The system static head (the difference in elevation
observing the gauges, will be able to maintain a maximum between the water level on the suction side of the
suction vacuum without cavitating the pump. pump and the point of discharge)

Piping System Design E. The length and size of suction and discharge lines,
With coarse settling slurries, the pipelines should be including a description of the general arrangement
vertical or horizontal. Inclined pipelines may surge due to including fittings, bends and valves
a backward drift or build up of solids. Also, an increase in
slurry friction loss may be experienced in these sloped F. If the discharge point is not to atmosphere, what is the
lines, further reducing performance. pressure, (e.g. cyclone backpressure).
25
 LCC

G. If suction is taken from a sump, provide the general

arrangement including size dimensions and minimum
and maximum sump levels referenced to the suction
centerline of the pump.

H. The available driver horsepower, speed of motor and

pump or description of the ratio device between the
pump and motor.

I. The impeller diameter if different from that supplied

with the pump.

The above items of data are especially important when a

pump has been transferred from the duty for which it was
selected to some other application.

In many instances, it will be found that unusual wear in the

pump, or low efficiencies, are caused by a mismatch
between the pump and the system application and can be
corrected once the operating conditions are known.

Contact your GIW / KSB representative for further specific

recommendations regarding system design. A useful
reference and textbook has also been published by GIW
titled: “Slurry Transport Using Centrifugal Pumps,” by
Wilson, Addie & Clift.

26
 LCC
8 Trouble Shooting e) Leaking caused by worn parts.
8.1 Low Flow Rate f) Excess wear of packing or sleeve:
a) Verify that the pump is correct for the system 1. Adjusting the packing too tight.
parameters in terms of flow and head. The pump 2. Insufficient flush flow or pressure.
curve can be used to determine the output, power and 3. Contaminated flush water.
speed. 4. Poor quality packing
b) Depending on the age and service of the pump, parts 5. Failure to lubricate new packing
could be worn sufficiently to reduce performance.
c) Verify that the motor has the correct power and 8.5 Overheating of Pump Casing
voltage required for the system, and is operating See Piping Connection section for details.
properly. a) Hot process fluid being pumped
d) Verify that the pump is running at the correct speed. b) Prolonged running against shut head or blocked
e) Verify that the suction side has adequate NPSH (Net discharge.
Positive Suction Head) as outlined in the pump NOTE: This is could create a Dangerous condition!!
specifications. c) Blocked suction
f) Check the suction pipe for air pockets, leaks, partially d) NPSH too low for pump.
closed valves or other restrictions. e) Air pockets in suction pipe or pump.
g) Be certain that the suction inlet and impeller are not
clogged. 8.6 Pump Leaking
h) Verify that the discharge valve is fully open. a) Defective gasket at pump flange.
b) Defective seal between pump casing, liner or housing.
8.2 Bearing Temperature c) Casing or liner worn through.
a) During the initial break in period, the bearings will d) Normal or excess stuffing box flow
normally run hotter as explained in the Initial Start Up
section. 8.7 Motor Overload
b) Excess temperature may be due hot process fluid a) Verify that the motor has the correct power and
c) Verify correct oil level. Overfilling causes viscous voltage supply, and is operating properly.
drag, which builds heat. b) Verify that the motor is correct for the pump. The
d) Verify oil viscosity. High viscosity and mineral oils pump specifications and curve can be used to
cause drag and build heat, especially at higher determine the power and speed required
speeds. c) Verify that the pumped fluid matches the system
e) Misalignment of the motor or coupling can create design viscosity and specific gravity.
excess bearing load and increased heat. d) Coupling misaligned.
f) Insufficient coupling clearance between the pump e) Gland adjusted too tight.
shaft and motor shaft can add axial loads to the thrust f) External pipe forces can distort the pump and bind the
bearings. motor and pump bearings.
g) External pipe forces can distort the pump and bind the g) Drag from external parts such as guards.
bearings.
h) Worn or damaged bearings may generate excess 8.8 Vibrations or Abnormal Noises
heat before failure. a) Cavitation due to low NPSH or blocked suction.
i) Drag from external parts such as coupling guards. b) Impeller rubbing due to incorrect nose adjustment.
c) Out of balance impeller.
8.3 Bearing Contamination d) Debris jammed in impeller vanes.
a) Excess leakage at stuffing box e) Pump or motor mounting bolts loose.
b) Damaged Inpro bearing isolator f) Improper shimming of overhead motor mount.
c) Improper maintenance g) Air in system.
d) Wrong lubricant h) Large solids in pumped fluid.
e) End cover seal damaged or missing i) Coupling misaligned.
j) Belts misaligned or incorrectly tightened.
8.4 Stuffing Box k) Insufficient clearance between the pump shaft and
See the Packing section for procedures. motor shaft at coupling.
a) High temperature due to packing adjusted too tight. l) Worn bearings in pump or motor.
b) High temperature due hot process fluid. m) Gland adjusted too tight.
c) Leaking caused by excess flush pressure. n) Vibrations from system transmitted through piping.
d) Leaking caused by wrong adjustment. o) Damaged or bent shaft in pump or motor.

27
 LCC
9 Torque Values for Metric Fasteners
(not otherwise specified)
Tightening Torque Values
Class 8.8 Metric Hex Head Capscrews
Metric Coarse & Fine Thread

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

Size in-lbs ft-lbs N-cm N-m in-lbs ft-lbs N-cm N-m in-lbs ft-lbs N-cm N-m
M4 X 0.7 28 316 21 236 17 190
M5 X 0.8 57 644 42 480 34 386
M6 X 1 95 1074 71 800 57 644
M8 X 1.25 228 2576 170 1919 137 1546
M8 X 1 239 2701 178 2012 143 1620
M10 X 1.5 468 38 5288 52 349 28 3940 38 281 23 3173 31
M10 X 1.25 38 52 28 38 23 31
M12 X 1.75 67 91 50 68 40 55
M12 X 1.25 70 95 52 71 42 57
M14 X 2 105 142 78 106 63 85
M14 X 1.5 111 150 83 112 67 90
M16 X 2 158 214 118 160 95 129
M16 X 1.5 166 225 124 168 100 135
M20 X 2.5 317 430 236 320 190 258
M20 X 1.5 339 460 253 342 203 276
M24 X 3 548 743 408 554 329 446
M24 X 2 575 780 428 581 345 468
M30 X 3.5 1098 1489 818 1109 659 893
M36 X 4 1914 2595 1426 1933 1148 1557

28
 LCC
NOTES

29
 LCC
10 General Drawing with List of Components
Pump assembly, bill of material and other drawing or special instructions relevant to each order will be attached to the back of
this manual.

11 Supplements
Supplements provide additional information for optional equipment. These options may not be available for your pump.
See your Bill of Materials for options that were included with your pump.

11. 1 Stuffing Box Throat Bushing Option

See page 31

11.2 Underwater Pump Operation with Duo-Cone Bearing Seals

See page 32

11. 3 Duo-Cone Seal

See pages 32-34

11. 4 Diverter
See page 35

30
 LCC
11.1 Stuffing Box Throat Bushing Option
(NON-EXPELLER)

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

Throat Bushing

Standard LCC Stuffing Box

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

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

• High operating pressure or temperature.

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

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

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

31
 LCC
11.2 Underwater Pump Operation with Duo-Cone Bearing Seals
The Underwater Cartridge Bearing Assembly (UCBA) uses Duo-Cone seals in the end cover. Sealing is accomplished with
two hardened, precision ground faces running against each other. An elastomer toric applies pressure to the faces and allows
the seal rings to accommodate axial and radial run out. The contact pressure and shaft speed will generate heat in the seal
faces that must be removed by the surrounding water as the pump is running. Correct installation and adjustment is extremely
critical to the proper function and life of these seals.

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

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

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

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

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

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

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 LCC
11.3 Duo-Cone Seals

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

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

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

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

33
 LCC
Final assembly is detailed on the Bearing Housing Assembly drawing. Bolt the end covers in
place and install the two (2) studs and nuts for the installation tool. Verify that there are no
burrs or sharp edges on the shaft that could damage the o-ring. Coat the long set screws with
anti-seize and thread them into the tapped holes until the points are 1/8” (3mm) from the inside
bore. Install the o-ring in the Seal Holder. Coat the ID of the holder with RTV silicone sealant,
including the o-ring and set screw holes. Place a small bead of silicone around the shaft
diameter to help the o-ring slide. Use extra care at the shaft keyway. Place the gap spacer
over the shaft and carefully slide the holder until it contacts the spacer. Drop the installation
tool over the shaft and tighten the nuts ¼ to ½ turn past Hand Tight against the tool.

The gap spacer should not move and the holder should contact it evenly on all sides. Tighten the set screws in a crisscross
pattern. Remove the installation tool and gap spacer, and then re-torque the set screws. Coat the lock screws with anti-seize
and tighten them in the tapped holes. Fill the tapped holes flush to the top with silicone to protect the set screws. This will
make removal easier for future maintenance. Rotate the shaft by hand and check for smooth operation. Verify that the holders
are square to the end cover. The metal seal rings may appear cocked slightly relative to the holders. This is not a problem, the
rings will run true when the pump starts.

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

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

Underwater Bearing
Shaft Size Assembly Oil Quantity
liters (quarts)
70mm 9.5 (10)
100mm 18.0 (19)
125mm 26.6 (26)

34
 LCC
11.4 Diverter
One of the product improvements to the GIW LCC Expeller pumps is the addition of a Diverter to further reduce the
accumulation of solids in the expeller chamber. This is a urethane part that is pressed into the hub area of the pump casing.
See the LCC Maintenance Manual for specific pump disassembly procedures.

Installation instructions:
Disable the driver to prevent pump operation
Drain the system and remove the suction pipe
Remove the suction liner and impeller
Clean the hub area of the pump casing
Removal of the pump casing will be necessary for the LCC 9 Metal & Rubber lined pumps, see figure below.
Clean the face of the expeller hub
Position the Diverter with the tapered ring facing into the pump as shown below
Press the Diverter completely back against the expeller plate –
If necessary, seat the Diverter using a small hammer and a smooth wood block cut to fit between the lip and casing
Place a small straight edge along the back of the pump casing to verify the diverter is flush to the casing plane within 3 mm.
Place two (2) new impeller release gaskets on the shaft
Coat the shaft threads with anti-seize
Thread the impeller on the shaft and hand tighten
Reinstall the suction liner and adjust the impeller nose gap
Connect the suction piping and restart the pump

35