KSB GIW MDX Installation instructions

Installation/Operating Manual
2017.01 MDX [en-US]
Pump Type:
Pump Serial Number:
Date:
Purchaser:
Purchaser’s Order Number:
GIW / KSB Work Order Number:
Shipped To:
Include the pump’s serial number when ordering replacement parts
This is a standard maintenance manual provided for your convenience
This manual may include additional documentation not applicable to your specific pump
GIW INDUSTRIES, INC.
5000 Wrightsboro Road
Grovetown, GA 30813 USA
[phone]
FAX [phone]
www.giwindustries.com
KSB AG
Johann-Klein-Str. 9
D-67227 Frankenthal, Germany
[phone] .
FAX [phone]
www.ksb.com

MDX [en-US]
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Legal Information/Copyright
Installation/Operating Manual MDX
Original operating manual (English)
In case of conflict between the local language version and the original operating manual, the original operating manual prevails.
A
ll rights reserved. Contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose,
nor otherwise transmitted, published or made available to a third party without KSB´s express written consent.
Subject to technical modification without prior notice.
© GIW Industries, Inc

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Contents
Section Page Section Page
1General 5
2Safety 6
2.1Safety Markings 6
2.2Personnel Qualification and Training 6
2.3Non-compliance with Safety Instructions 7
2.4Safety Awareness 7
2.5Safety Instructions for Operators 7
2.6Safety Instructions for Maintenance, Inspection &
Installation 7
2.7Unauthorized Modification and Manufacture of Spare Parts 7
2.8Unauthorized Modes of Operation 7
2.9Assembly & Disassembly Safety 7
3Transport and Storage 9
3.1Transport & Handling Safety 9
3.2Storage Requirements 9
3.2.1Storage of New Pumps - Pumps under Warranty 9
3.2.2Pump Storage 9
3.2.3Pump Parts Storage 11
3.2.4Removal from Storage 12
3.3Recommended Lifting 13
4Description 14
4.1Technical Specification 14
4.2Designation 14
4.3Design Features 14
4.4Noise Characteristics 14
4.5Accessories 15
4.6Dimensions and Weights 15
4.7Forces and Moments at Nozzles 16
5Installation at Site 17
5.1Safety Regulations 17
5.2Foundation 17
5.3Installing the Baseplate and Pump 17
5.3.1Aligning the Pump / Drive Train for Horizontal Pump
Application 17
5.3.2Place of Installation 18
5.4Connecting the Piping 19
5.4.1Auxiliary Connections 19
5.5Safety Guards 19
5.6Oil Temperature Monitoring 19
5.7Final Check 19
5.8Connection to Power Supply 19
6Commissioning / Operation 20
6.1Commissioning / Return to Service 20
6.1.1Bearing Lubrication 20
6.1.2Shaft Seal Commissioning 21
6.1.3Checking the Direction of Rotation 21
6.1.4Cleaning the Plant Piping 22
6.1.5Suction Strainer 22
6.2Start-up 22
6.2.1Priming the Pump 22
6.3Shutdown 23
6.3.1Measures to be taken for Prolonged Shutdown 23
6.4Operating Limits 23
6.4.1Temperature Limits 23
6.4.2Switching Frequency 23
6.4.3Density of the Medium Handled 24
6.5Underwater Pump Operation 24
7Maintenance 25
7.1Supervision of Operation 25
7.2Drainage / Disposal 25
7.3Lubrication and Lubricant Change 25
7.3.1Underwater Operation 25
7.4Procedures for Maximum Parts Life 26
7.5Operational Problems and Solutions 26
8Mechanical End 28
8.1Mechanical End Overview 28
8.2Mechanical End Disassembly 28
8.3Mechanical End Assembly 29
8.3.1Mounting the Bearings 29
8.3.2Closing the Housing 30
8.3.3Installing End Covers and Seals 31
8.4Bearing Assembly Mounting 31
9Shaft Seal 34
9.1Mechanical Seal 34
9.1.1Mechanical Seal Assembly and Disassembly 34
9.2Stuffing Box 34
9.2.1Stuffing Box Packing 35
9.2.2Stuffing Box Assembly 35
9.2.3Stuffing Box Maintenance 35
10Wet End 37
10.1Wet End Overview 37
10.2Wet End Disassembly 37
10.2.1Adjustable Suction Liner Removal 37
10.2.2Impeller Removal with Release Ring Assemblies 38
10.2.3Impeller Removal with Optional Release Ring Tool 38
10.2.4Impeller Break-Loose Device 40
10.2.5Impeller Removal with Impeller Lifting Device 40
10.2.6Casing Removal 40
10.3Wet End Assembly 40
10.3.1Mounting the Shaft Sleeve 41
10.3.2Hub Plate (if applicable) 42
10.3.3Mounting the Casing 42
10.3.4Impeller Installation 43
10.3.5Mounting the Suction Plate / Liner 43
10.3.6Snap Ring Gasket 45
10.3.7Suction Liner Adjustment 46
10.4Setting the Nose Gap 47
11Tooling 49
11.1Torque Requirements 49
11.2Spare Parts Stock 50
12Troubleshooting 51
14Notes 53

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Index
Section Page Section Page
Accessories 15
Alignment 17
Assembly Safety 7
Assembly, Mechanical End 29
Assembly, Wet End 40
Auxiliary Connections 19
Baseplate 17
Bearing Assembly Mounting 31
Bearing Housing Assembly 30
Bearing Installation 29
Bearing Lubrication, Commissioning 20
Casing 37
Casing Installation 42
Casing Removal 40
Cavitation / NPSH Performance 26
Commissioning 20
Commissioning / Return to Service 20
Commissioning, Bearing Lubrication 20
Density of the Medium Handled 24
Dimensions 15
Direction of Rotation 21
Disassembly Safety 7
Disassembly, Mechanical End 28
Disassembly, Wet End 37
Drainage / Disposal 25
End Covers and Seals, Installation 31
Foundation 17
Hub Plate Installation 42
Impeller 37
Impeller Installation 43
Impeller Removal, Break-Loose Device 40
Impeller Removal, Lifting Device 40
Impeller Removal, Optional Release Ring Tooling 38
Impeller Removal, Release Ring 38
Impeller, Parts Life 26
Inspection, Safety 7
Installation 17
Installation, Location 18
Installation, Safety 7
Lifting 13
Lubricant Change 25
Maintenance Equipment 49
Maintenance, Safety 7
Mechanical End 28
Mechanical End Assembly 29
Mechanical End Disassembly 28
Mechanical Seal 34
Mechanical Seal Assembly and Disassembly 34
Mechanical Seals, Commissioning 21
Mounting the Bearings 29
Noise Characteristics 14
Nose Gap Adjustment 47
Oil Temperature Monitoring 19
Operating Conditions of Flow and Head 27
Operating Limits 23
Operation 20
Operation, Unauthorized Modes 7
Operational Problems and Solutions 26
Packing 35
Parts Life 26
Personnel 6
Piping System Design 26
Piping, Allowable Forces and Moments 16
Piping, Cleaning 22
Piping, Connecting 19
Power Supply 19
Priming the Pump 22
Pump Casing, Parts Life 26
Pump Description 14
Pump Design Features 14
Pump Designation 14
Pump Specification 14
RTD Installation 19
Safety Awareness 7
Safety Guards 19
Safety Markings 6
Safety, Final Check 19
Safety, Non-compliance 7
Safety, Operators 7
Safety, Regulations 17
Safety, Transport & Handling 9
Seal Water Requirements 35
Shaft Seal 34
Shaft Seal, Commissioning 21
Shaft Sleeve, Mounting 41
Shutdown 23
Shutdown, Prolonged 23
Snap Ring Gasket 45
Spare Parts Stock 50
Spare Parts, Unauthorized Modification 7
Start-up 22
Storage Requirements 9
Stuffing Box 34
Stuffing Box Assembly 35
Stuffing Box Maintenance 35
Stuffing Box, Commissioning 21
Suction Liner Adjustment 46
Suction Liner Installation 43
Suction Liner, Parts Life 26
Suction Plate / Liner Removal 37
Suction Strainer 22
Sump Design 26
Switching Frequency 23
Temperature Limits 23
Tooling 49
Torque Requirements 49
Transport, Storage & Handling 9
Troubleshooting 51
Underwater Operation 25
Underwater Pump Operation 24
Wear Problems and Solutions 26
Weights 15
Wet End 37
Wet End Assembly 40
Wet End Disassembly 37

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1 General
CAUTION
This manual contains important information for reliable, proper and efficient operation. Compliance with the
operating instructions is of vital importance to ensure reliability and long service life of the pump, and to avoid
any risks.
These operating instructions do not take into account local regulations; the operator must ensure that such regulations are strictly
observed by all, including the personnel called in for installation.
WARNING
This pump / unit must not be operated beyond the limit values specified in the technical documentation for the
medium handled, capacity, speed, density, pressure, temperature and motor rating. Make sure that operation is
in accordance with the instructions given in this manual or in the contract documentation.
The nameplate indicates the type series / size, main operating data and serial number. Please quote this information in all
queries, repeat orders and particularly when ordering spare parts.
This manual may contain information not applicable to your pump/unit. Your pump/unit may not be equipped with all features or
auxillary components as described in this manual. Consult your pump/unit drawings and Bill of Materials for details.
If you need any additional information or instructions exceeding the scope of this manual or in case of damage, please contact
your GIW / KSB representative.

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2 Safety
These operating instructions contain fundamental information that must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read and understood both by the installing personnel and the responsible
trained personnel / operators prior to installation and commissioning, and it must always be kept close to the operating location
of the machine / unit for easy access.
Not only must the general safety instructions given in this chapter of "Safety" be complied with, but also the safety instructions
outlined under specific headings.
2.1 Safety Markings
Definition of safety symbols/markings
Symbol Description
DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided, will result in death or
serious injury.
WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not avoided, could result in death
or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could result in damage to the
machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in potentially explosive
atmospheres in accordance with EC Directive 94/9/EC (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a hazard which will or could
result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a hazard involving electrical
voltage and identifies information about protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine
and its functions.
Instructions attached directly to the machine, such as:
 Arrow indicating the direction of rotation
 Marking for fluid connections must always be complied with and be kept in legible condition at all times.
2.2 Personnel Qualification and Training
All personnel involved in the operation, maintenance, inspection and installation of the machine must be fully qualified to carry
out the work involved.
Personnel responsibilities, competence and supervision must be clearly defined by the operator. If the personnel in question are
not already in possession of the requisite know-how, appropriate training and instruction must be provided. If required, the
operator may commission the manufacturer / supplier to provide such training. In addition, the operator is responsible for
ensuring that the contents of the operating instructions are fully understood by the responsible personnel.

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2.3 Non-compliance with Safety Instructions
Non-compliance with safety instructions can jeopardize the safety of personnel, the environment and the machine itself. Non-
compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
Failure of important machine / unit functions
 Failure of prescribed maintenance and servicing practices
 Hazard to persons by electrical, mechanical and chemical effects
 Hazard to the environment due to leakage of hazardous substances.
2.4 Safety Awareness
It is imperative to comply with the safety instructions contained in this manual, the relevant national and local health and safety
regulations and the operator’s own internal work, operation and safety regulations.
2.5 Safety Instructions for Operators
 Any hot or cold components that could pose a hazard must be equipped with a guard by the operator.
 Guards that are fitted to prevent accidental contact with moving parts (e.g. coupling) must not be removed while the
machine is operating.
 Leakages (e.g. at the shaft seal) of hazardous media handled (e.g. explosive, toxic, hot) must be contained so as to
avoid any danger to persons and the environment. Pertinent legal provisions must be adhered to.
 Electrical hazards must be eliminated. (Refer to the relevant safety regulations applicable to different countries and /
or the local energy supply companies.)
 Mixing unsuitable media may cause a chemical reaction resulting in a pressure buildup and potential explosion.
2.6 Safety Instructions for Maintenance, Inspection & Installation
 The operator is responsible for ensuring that all maintenance, inspection and installation work is performed by
authorized and qualified personnel who are thoroughly familiar with the manual.
 Work on the machine must be carried out only during standstill. The shutdown procedure described in the manual for
taking the machine out of service must be adhered to without fail.
 Pumps or pump units handling media injurious to health must be decontaminated.
 Immediately following completion of the work, all safety / protective devices must be re-installed and / or re-activated.
 Please observe all instructions set out in the Section 6 "Commissioning" before returning the machine to service.
2.7 Unauthorized Modification and Manufacture of Spare Parts
Modifications or alterations of the machine are only permitted after consultation with the manufacturer. Original spare parts and
accessories authorized by the manufacturer ensure safety. The use of other parts can invalidate any liability of the manufacturer
for damage or warranty.
2.8 Unauthorized Modes of Operation
Any warranty of the operating reliability and safety of the pump / unit supplied is only valid if the machine is operated in
accordance with its designated use as described in the following sections. The limits stated in the data sheet must not be
exceeded under any circumstances.
2.9 Assembly & Disassembly Safety
DANGER
Do not apply heat to the impeller hub or nose due to the sealed cavity at the impeller nose.
DANGER OF EXPLOSION!
For sectional drawings and bills of material relating to your specific pump and equipment, locate an official copy of the
documentation provided by GIW / KSB. This may be shipped separately from the pump and will include drawings and bills
of material as attachments to this basic manual.
 Dismantling and reassembly must always be carried out in accordance with the rules of sound engineering practice
and the relevant sectional drawings. Any work on the motor, gear reducer, mechanical seal or other non-pump
equipment shall be governed by the specifications and regulations of the respective supplier.
 Before assembly thoroughly clean all dismantled part mating surfaces 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. It is recommended that new seal elements (o-rings and gaskets) be used
whenever the pump is reassembled. Make sure that new gaskets have the same thickness as the old ones.

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 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 mounting aids or anti-adhesives other
than those described are required, please contact the sealing material manufacturer.
 The operator is responsible for ensuring that all maintenance inspection and installation work is carried out by
authorized, duly qualified staff who are thoroughly familiar with these operating instructions.
 A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of
the pump with a minimum of maintenance expenditure.
 Repair and maintenance work to the pump must only be carried out by specially trained personnel, using original
equipment spare parts.
WARNING
 Proper lifting, rigging and safety practices must be observed at all times. Do not attempt to lift heavy
components by hand as this may result in personal injury and damage to equipment.
 Work on the unit must only be carried out with the electrical connections disconnected and locked out.
Make sure that the pump set cannot be switched on accidentally.
 Pumps handling liquids posing health hazards must be decontaminated. When draining the medium
ensure there is no risk to persons or the environment. All relevant laws must be adhered to.
 Before dismantling or reassembly, 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, drained, and its pressure must be released.
 Before dismantling or reassembly of vertical cantilever pumps, remove the motor and pull the assembly
out of the sump.
 Upon completion of the work, all safety-related and protective equipment must be properly refitted
and/or reactivated before starting the pump set.
 Always ensure that lifting equipment does not bind the swivel hoist ring. Binding can cause the ring to
fail. When lifting a plate that contains two swivel hoist rings, do not allow the angle between the lines
of tension from the rings to exceed 120°. This could cause the hoist rings to fail.
Do NOT bind lifting equipment Do NOT exceed 120° between lines of tension
120
°

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3 Transport and Storage
3.1 Transport & Handling Safety
WARNING
 Proper rigging, lifting and safety practices must be observed at all times.
 If the pump / unit slips out of the suspension arrangement, it may cause personal injury and damage
to property.
 Follow proper lifting practice and safety rules at all times, including:
 Verification of the lift weight and load rating of the lift equipment.
 Suitability and stability of the attachment points.
 Be aware of the location of the center of gravity, which is usually NOT located at the physical center of the unit. In
general, the following guidelines will apply, although common sense and testing of the lift before movement should be
used to verify:
 Bare shaft pump (without motor): Near the shaft seal area.
 Pump with overhead mounted motor: Between the pump and motor, slightly behind (towards the drive end) of
the shaft seal.
 Vertical cantilever pump: between the pump and bearing assembly, but closer to the bearing assembly.
 Space the lifting points evenly about the center of gravity and as far apart as practical. This will result in the most stable
lift. Note that certain lift points on the pedestal or bearing housing may be intended for use in handling the pedestal or
bearing house alone and are not necessarily optimum balance points for the entire pump unit.
 See Section 3.3 or any addendums for suggested lifting methods. Actual safe lifting method will vary with pump
configuration and type of lifting equipment.
 Ensure secure attachments and test the lifting method for stability before moving pump.
 For horizontal pumps, ensure that the unit remains in the horizontal position during lifting and cannot slip out of the
suspension arrangement.
 Ensure that the pump is firmly strapped down during shipment. Pump should be protected from direct contact with the
elements. Motors and gear reducers may require Immediate cover (consult manufacturer). After arrival on site, consult
GIW Pump Storage recommendations for further storage instructions.
 In corrosive environments be sure to remove all lifting devices from the pump and store in a non-corrosive environment
until needed.
 DO NOT: Use eyebolt or shackle locations on the bearing assembly, motor or pump plates. These are intended for
lifting those items alone and must not be used when lifting the entire pump.
 DO NOT: Place excessive side loads on cast lifting eyes. The side loading angle on any lifting eye should not exceed
30 degrees.
3.2 Storage Requirements
3.2.1 Storage of New Pumps - Pumps under Warranty
Consult your sales contract documents and/or your GIW / KSB representative for detailed instructions. Note that failure to follow
proper storage procedures will void your warranty.
3.2.2 Pump Storage
CAUTION
 In freezing environments, water must be prevented from collecting in the pump casing.
 Pumps with elastomer linings should be stored in a cool dark location free from electrical equipment
such as motors, or any other ozone generating devices. Exposure to direct sunlight or temperatures in
excess of 50°C (120°F) must be avoided.
 If the pump is fitted with a mechanical seal, motor, sheave, bushing, coupling, gear reducer, or other
auxilarily equipment be sure to consult the manufacturer’s maintenance manual for any additional
storage instructions.
 Auxiliary systems should be regularly tested according to manufacturer’s recommendations.

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Storage Upon Receipt and up to 3 Months:
 Pump should stored indoors and out of the weather until ready for installation.
 In construction environments where indoor storage is not available, store the pump on blocks or pallets, build a frame
around it and cover with tarpaulin.
o Frame must be able to withstand snow and wind, anchored and built in a manner to last the entire time pump
is in storage. Shelter must be continuously maintained in a stable and leak free condition.
o Ensure the tarpaulin does not touch the pump, since this can lead to condensation. Leave the bottom open
for ventilation. Minimum Tarp requirements: 610gsm (18oz) Vinyl, 0.5mm (20mil) thick, Water proof & UV
(ultraviolet) resistant
Storage Exceeding 3 Months
 If pump is exposed to the weather at any time the frame requirements still stand.
 The Wet End pump parts should be drained and isolated from reaction vessel gasses.
 Check the rust inhibitor coatings on bare metal surfaces and renew exposed areas.
 Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
 Check that the threaded holes are protected with grease and plugged.
 Oil lubricated bearing assemblies with GIW Blue Oil (requires shaft rotation):
o GIW Blue Oil supplied with the pump should be added to the bearing housing until the level is halfway of the
Oil Sight Glass (642).
o Pump shaft should be manually rotated approximately 5 turns each month to keep the bearings coated.
o Vertical pumps should have the Lubrication Oil System running while the shaft is rotated 5 turns each month.
o The oil should be replaced if shutdown duration exceeds 12 months.
 Oil lubricated bearing assemblies with GIW Storage Oil (alternative to shaft rotation):
o GIW Storage Oil should be added to the bearing housing until the level is halfway of the Oil Sight Glass (642)
and rotate the shaft several times. No further shaft rotation is needed
o The bearing assembly must remain sealed in the factory assembled condition. The oil fill plug must be securely
replaced and no breather or other vent added to the bearing housing.
o Vertical pumps should be stored horizontally and filled with Storage Oil to the center of the sight glass or
25mm (1 inch) below the largest diameter Inpro/Seal bearing isolator, whichever is lower.
o The storage oil should be replaced if shutdown duration exceeds 12 months.
 Grease lubricated bearing assemblies do not require monthly rotation.
 If the pump is fitted with a mechanical seal, precautions may need to be taken before rotating the shaft. Refer to the
seal manufacturer’s maintenance manual for instructions.
 Pumps with InPro/Seal® bearing isolators must be coated externally with white grease or petroleum jelly to seal the
gap between the rotor and stator. Units equipped with a vent kit must have the vents either removed and plugged, or
blocked to prevent air exchange.
 Vertical pumps should be stored horizontally, and the blocking on the shaft should be left in place until the pump is
ready to be installed.
Storage Exceeding 12 Months (Long Term Storage)
The following information on long term storage pertains to GIW pump assemblies only and does NOT cover any auxiliary
equipment such as motors, gearboxes, lube oil systems, etc... Long term storage for auxiliary equipment must be included in
the contract and negotiated with sub-vendors at time of order.
At 12 months storage and again at 24 months of storage, the following additional actions should be taken:
 Check the rust inhibitor coatings on bare metal surfaces and renew exposed areas.
 Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
 Replace the GIW Oil and/or Storage Oil, if applicable.
Installed Spares (Idle Pumps)
 After being idle to 1 or more months, shafts must be rotated through five (5) or more revolutions, either manually or by
a short duration start-up. If regularly exposed to moisture (weather or process related), monthly oil analysis is
recommended since idle bearing assemblies are subject to breathing and internal condensation due to ambient
temperature fluctuations.
 After being idle for 3 or more months, oil change or oil analysis is recommended for all pumps to ensure against
condensation.
 After being idle for 12 months or more, the oil should be replaced.

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3.2.3 Pump Parts Storage
CAUTION
For proper storage ensure:
 All machined surfaces must be coated with rust protector
 Grease and plug all drilled and threaded holes
 Check monthly for paint breakdown on casting
 Check monthly for visible sign of rust on machine surface
 Check monthly forgeign matter buildup in drilled/threaded holes
 Remove rust with wire brush and recoat machined surfaces with a rust inhibitor as needed
 Remove rust with wire brush and repaint casting surfaces as needed
All pump parts must be stored indoors. The only exception is for large castings such as pedestals, pump casings,
impellers, etc… See chart below for details.
Pump Part Storage Requirements
Pedestal
Casing
Casing Half
Liner
Plate
Impeller
Sub-base
 Outdoor storage with monthly inspection permitted for these parts only
 Lay sub-bases flat and do not stack
Rubber
Elastomers
Urethane
Neoprene
 Check expiration date (shelf life is 5 years)
 Keep dry, out of direct sunlight or other UV (ultraviolet) sources and away from heat.
 Store in the box with part being covered with the black plastic, low density,
polyethylene bags (4mil/0.10mm minimum thickness) and re-seal the boxes.
 Periodically inspect for the presence of a soft chalky layer, easily rubbed off, which
would indicate deterioration
 Darkening or discoloration of elastomer parts over time is a natural occurrence and
does not by itself indicate any loss of properties.
Shaft Sleeve
Lantern Ring
Wear Plate
 Coat complete part with rust protector
Shaft  Coat complete part with rust protector and wrap with 6mil/0.15mm VCI (Vapor
Corrosion Inhibitor ) plastic
O-Ring
Gasket
 Check expiration date (shelf life is typically 5 years)
 Keep dry, out of direct sunlight and away from heat
Bearing
Bearing Isolator
Sealing Washer
 Check expiration date (shelf life is typically 1 year)
 Refer to Manufacturer’s Storage guidelines
 Keep in unopened box provided by the vendor
 Keep dry, out of direct sunlight and lay flat
Motor
Sheave
Gear Reducer
Coupling
Bushing
 Refer to manufacturer’s storage guidelines

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3.2.4 Removal from Storage
 Remove rust from machined surfaces using a wire brush.
 Remove rust inhibitor from all machined surfaces prior to installation/assembly.
 Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
 It is recommended that the bearing assembly be drained before shipment and refilled after relocation or installation.
 If GIW Blue Oil with rotation was used and the pump is stored for less than 12 months, the same oil may be used for
initial commissioning and break in. Otherwise, it is recommended that the oil be replaced prior to commissioning to
remove any moisture.
 If GIW Storage Oil was used, it should be drained and replaced with GIW Blue Oil before start-up.
 For grease lubricated units, a fresh application of grease in the amount recommended by the maintenance manual for
a normal lubrication interval should be applied.
 Stuffing Box should be checked before start-up and replaced if necessary. Packing may have dried out and need
multiple readjustments during the start-up process.
 If the pump is fitted with a mechanical seal, motor, sheave, bushing, coupling, gear reducer, or other auxilarily
equipment be sure to consult the manufacturer’s maintenance manual for any additional storage removal and
commissioning instructions.Consult the Section 6 "Commissioning" before putting the pump into service.

MDX [en-US]
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3.3 Recommended Lifting
WARNING
Actual safe lifting method will vary with pump configuration and type of lifting equipment
1 Alternate
Transport of the pump
1

MDX [en-US]
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4 Description
4.1 Technical Specification
This pump range has been designed to the Imperial system of units using Imperial dimensioned components, fasteners and
sealing elements. In some special cases Metric components have been used. Please consult your arrangement drawings
and bills-of-material for details concerning your equipment.
Tooling used for assembly and maintenance of fasteners and other components should be according to the correct Imperial
or Metric standard. Spare parts such as oil seals, o-rings and stuffing box packing should also be purchased in the correct
Imperial or Metric size. Crossover between Imperial and Metric tools or spare parts is generally not recommended.
Contact your GIW / KSB representative for specific problems or questions.
The MDX is a centrifugal pump for handling highly abrasive slurries for mill circuit applications. Applications include SAG (Semi-
Autogenous Grinding) and ball mill discharge; mill transfer; cyclone and screen feed.
4.2 Designation
Example Designation: MDX 150-650.5 G L B T MM
Pump Type
Discharge Nozzle (mm)
Nominal Impeller Diameter (mm)
Shaft Size
Plug Type
Bearing Assembly Type
Seal Type
Lantern Ring Material
Suction Liner Material
Hub Liner Material
Shaft Size
3 3 - 15/16
5 5 - 7/16
6 6 - 7/16
7 7 - 3/16
9 9
10 10 - 1/4
11 11 - 1/2
Plug Type
F 3.5S
G 2C4.5
J 6.5
K
7.75
L 9.0
M 11.5
Bearing Assembly Type
L Limited End Float
C Conventional
Seal Type
F Forward Flush
K KE Design
M Mechanical Seal
B Throat Bushing
S SpiralTrac™
Lantern Ring Material
T Teflon
M Metal
N Not Applicable
Suction/Hub Liner
Material
M Metal
R Rubber
N Not Applicable
For additional information please contact your GIW / KSB representative.
4.3 Design Features
Horizontal, end suction, modified volute casing pump with heavy section thickness and 3-, 4- or 5-vane impellers for the optimum
solids passage and performance. Single wall, heavy section, hard metal wet end combined with robust cartridge bearing
assembly provides maximum reliability and ease of maintenance.
The standard MDX is a single wall, hard metal configuration in discharge sizes 6 inch (152mm) to 30 inch (762mm). Other
custom produced (CP) and custom engineered (CE) configurations are available upon request.
4.4 Noise Characteristics
WARNING
The addition of coarse solids, froth or cavitating conditions can significantly increase the noise levels in both the
pump and piping. If accurate noise levels are required for these conditions, field-testing will be required.
If running within the normal limits of operation and with clear water, the noise level for the pump alone (with gear box and motor
noises shielded) does not exceed 85 dB(A) at one meter.
Noise levels from motor and gear reducer must be added to the above in accordance with standard acoustic formulas, taking
into account the distance between units. For belt driven units, add an additional 2 dB.

MDX [en-US]
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4.5 Accessories
Couplings, pulleys, belts, motor mounts and/or base plates may be provided. Refer to the bill-of-materials, data sheets and/or
drawings for further information.
4.6 Dimensions and Weights
Dimensions and weights are listed on the pump installation plan.

MDX [en-US]
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4.7 Forces and Moments at Nozzles
Below are the allowable combined branch loads applicable for all GIW slurry pumps.
Methods based on ANSI/HI 12.1-12.6-2011 Slurry Pump Standard. 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 / KSB Application Engineer for more
information.
NOTE: Discharge branch coordinate system always moves with the branch angle.
(Fz is always along the direction of flow).
Flange Size Allowable Forces Allowable Moments
FX F
Y F Z M X M Y M Z
inch mm lbs N lbs N lbs N ft-lbs N-m ft-lbs N-m ft-lbs N-m
DISCHARGE PIPE
2 50 1600 7110 1280 5690 3250 14450 2640 3570 2640 3570 4000 5420
3 75 1760 7840 1410 6270 3410 15180 2900 3930 2900 3930 4390 5960
4 100 1930 8590 1550 6890 3580 15930 3160 4290 3160 4290 4790 6500
6 150 2270 10110 1820 8090 3920 17450 3680 4990 3680 4990 5580 7570
8 200 2630 11700 2100 9340 4280 19040 4200 5690 4200 5690 6360 8620
10 250 3010 13390 2410 10710 4660 20730 4700 6380 4700 6380 7130 9670
12 300 3420 15230 2740 12180 5070 22560 5210 7070 5210 7070 7900 10710
14 350 3890 17300 3110 13830 5540 24640 5710 7740 5710 7740 8650 11730
16 400 4440 19760 3550 15790 6090 27100 6200 8410 6200 8410 9400 12750
18 450 5110 22750 4090 18190 6760 30090 6690 9070 6690 9070 10140 13750
20 500 5900 26240 4720 20990 7550 33580 7170 9730 7170 9730 10870 14740
22 550 6680 29730 5350 23790 8330 37070 7650 10380 7650 10380 11600 15720
24 600 7350 32720 5890 26190 9000 40060 8120 11020 8120 11020 12310 16700
26 650 7900 35170 6330 28150 9550 42510 8590 11650 8590 11650 13020 17660
30 750 8780 39090 7030 31260 10430 46430 9510 12900 9510 12900 14410 19540
36 900 9860 43890 7890 35090 11510 51230 10850 14710 10850 14710 16440 22290
38 950 10150 45170 8120 36150 11820 52580 11280 15300 11280 15300 17100 23190
SUCTION PIPE
3 75 3410 15180 1760 7840 1410 6270 4390 5960 2900 3930 2900 3930
4 100 3580 15930 1930 8590 1550 6890 4790 6500 3160 4290 3160 4290
6 150 3920 17450 2270 10110 1820 8090 5580 7570 3680 4990 3680 4990
8 200 4280 19040 2630 11700 2100 9340 6360 8620 4200 5690 4200 5690
10 250 4660 20730 3010 13390 2410 10710 7130 9670 4700 6380 4700 6380
12 300 5070 22560 3420 15230 2740 12180 7900 10710 5210 7070 5210 7070
14 350 5540 24640 3890 17300 3110 13830 8650 11730 5710 7740 5710 7740
16 400 6090 27100 4440 19760 3550 15790 9400 12750 6200 8410 6200 8410
18 450 6760 30090 5110 22750 4090 18190 10140 13750 6690 9070 6690 9070
20 500 7550 33580 5900 26240 4720 20990 10870 14740 7170 9730 7170 9730
22 550 8330 37070 6680 29730 5350 23790 11600 15720 7650 10380 7650 10380
24 600 9000 40060 7350 32720 5890 26190 12310 16700 8120 11020 8120 11020
26 650 9550 42510 7900 35170 6330 28150 13020 17660 8590 11650 8590 11650
28 700 10020 44590 8370 37250 6700 29800 13720 18600 9050 12280 9050 12280
30 750 10430 46430 8780 39090 7030 31260 14410 19540 9510 12900 9510 12900
34 850 11170 49710 9520 42370 7620 33890 15770 21390 10410 14110 10410 14110
36 900 11510 51230 9860 43890 7890 35090 16440 22290 10850 14710 10850 14710
38 950 11820 52580 10150 45170 8120 36150 17100 23190 11280 15300 11280 15300
F
zd
M
zd
F
yd
M
yd
F
xd
M
xd
F
zs
M
zs
M
ys
F
ys
F
xs
M
xs

MDX [en-US]
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5 Installation at Site
5.1 Safety Regulations
WARNING
Electrical equipment operated in hazardous locations must comply with the applicable explosion protection
regulations. This is indicated on the motor rating plate. If the equipment is installed in hazardous locations, the
applicable local explosion protection regulations and the regulations of the test certificate supplied with the
equipment and issued by the responsible approval authorities must be observed and complied with. The test
certificate must be kept close to the location of operation for easy access.
5.2 Foundation
WARNING
Appropriate personal protective equipment should be worn when handling concrete and grouting materials.
All structural work required must have been prepared in accordance with the dimensions stated in the dimension table /
installation plan.
The concrete foundation shall have sufficient strength for the pump and be completely cured before installation. The mounting
surface must be flat and level. Anchor bolts must be located according to the installation plan. This can be done when the
concrete is poured, or by drilling holes in existing foundations and grouting the bolts in place.
5.3 Installing the Baseplate and Pump
WARNING
Do not install the baseplate and pump on unpaved or unsupported foundations. Injury can result from vibration
or shifting equipment.
After placing the baseplate on the foundation, it must be leveled by shimming. Shims should be fitted between the baseplate
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 of more than 800mm (30 inch), additional shims should be inserted halfway between
the adjoining holes. All shims must lie perfectly flush.
Insert the foundation bolts and set them into the foundation using concrete. When the mortar has set, tighten the foundation
bolts evenly and firmly and grout the baseplate using low shrinkage grout.
1 Shim
2 Foundation Bolts
3 ≤ 800 mm
5.3.1 Aligning the Pump / Drive Train for Horizontal Pump Application
WARNING
 Use of the mounting bolts to close gaps between motor feet and the mounting plate (in place of
shimming) is not recommended and may result in twisting of the motor frame, "soft foot" mounting and
excessive vibration.
 Care must be taken when removing drive components to avoid personal injury or damage to the
equipment. Avoid contact with hot surfaces such as couplings, which may heat up during normal
operation and cause injury.
3
1 1
1
2

MDX [en-US]
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CAUTION
 All components must be level during system operation unless special provisions for bearing lubrication
and oil sealing have been made. After attaching the unit to the foundation and connecting the piping,
the pump and drive train must be thoroughly checked and, if necessary, realigned.
 Improper alignment of the unit can cause damage to both the coupling and the unit itself.
 Proper alignment must be taken into consideration when using an overhead motor mount accessory. Motor feet
must be firmly supported at each mounting bolt location before the bolts are tightened. Shims should be used to
fill any gaps and ensure solid mounting and vibration prevention.
 For optimum performance, the pump should be mounted directly to the
baseplate without shims. The rest of the drive train is then aligned to the pump.
For this reason, GIW baseplate designs generally allow space for shimming
under the gear reducer and motor, but not under the pump itself. The only
exception occurs in cases where regular removal and replacement of the entire
pump is stipulated during the equipment design stage. In these cases, special
instructions for alignment and shimming of the pump may be given on the pump
assembly and/or general arrangement drawings.
 Checks and realignment must be done even if pump and motor are supplied
completely assembled and aligned on a common base plate. The correct
distance between the coupling halves and pulleys as specified in the
installation plan must be observed.
 The pump set is correctly aligned if a straightedge placed axially on both
coupling halves is the same distance from each shaft at all points around the
circumference. In addition, the distance between the two coupling halves must
remain the same all around the circumference. Use a feeler gauge, a wedge
gauge or a dial micrometer to verify.
 The radial and axial deviation (tolerance) between the two coupling halves
should not exceed 0.1 mm (0.004 inch).
 Ensure that coupling gaps are properly set in the case of motors with sleeve
bearings.
 For V-belt installations, the pulleys are correctly aligned if a straightedge placed
vertically shows a deviation of no more than 1.0 mm (0.04 inch). Both pulleys
must be parallel.
V-belt Pulley Alignment
1 Align
2 Maximum 1mm
3 Straight Edge
4 Gauge
Angular Misalignment Offset Misalignment
RPM Excellent Acceptable Excellent Acceptable
≤ 900 1.0 µm
mm 1.5 µm mm 100 µm 200 µm
≤ 1200 0.7 µm
mm 1.0 µm mm 75 µm 150 µm
≤ 1800 0.5 µm
mm 0.7 µm mm 50 µm 100 µm
≤ 3600 0.3 µm
mm 0.5 µm mm 25 µm 50 µm
Coupling Alignment Typical industry standard for coupling alignment
5.3.2 Place of Installation
WARNING
The volute casing and shaft seal take on roughly the same temperature as the medium handled.
The shaft seal seal, bearing assembly and bearing housing must not be insulated.
Take the necessary precautions to avoid burns to personnel and adjacent equipment.
1
2
3
4

MDX [en-US]
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5.4 Connecting the Piping
WARNING
Danger of life when toxic or hot media are handled.
CAUTION
Never use the pump itself as an anchorage point for the piping.
Permissible forces and moments must not be exceeded (see to section 4.7).
Refer to your drawing for spool piece recommendation to ease maintenance.
 Thermal expansions of the pipelines must be compensated by appropriate measures so as not to impose any extra
loads on the pump exceeding the permissible pipeline forces and moments.
 An excessive, impermissible increase in the pipeline forces may cause leaks on the pump where the medium handled
can escape into the atmosphere.
 The flange covers on the pump suction and discharge nozzles must be removed prior to installation in the piping.
5.4.1 Auxiliary Connections
CAUTION
These connections are required for proper functioning of the pump and are therefore of vital importance!
The dimensions and locations of the auxiliary connections (cooling, heating, sealing liquid, flushing liquid, etc.)
are indicated on the installation plan or piping layout.
5.5 Safety Guards
WARNING
In compliance with the accident prevention regulations the pump must not be operated without coupling and
drive guards. If the customer specifically requests not to include guards in our delivery, then the operator must
supply them.
5.6 Oil Temperature Monitoring
RTD (Resistance Temperature Detector) units are usually shipped separately along with the fittings needed to install them. Care
should be taken during assembly. Any fittings should be assembled and installed in the bearing housing before installing the
RTD units. Use an oil compatible sealer on the threads during installation. Be sure to tighten fittings so that any oil drain plug is
facing in the down position. After all fittings are installed, install the RTD unit. Take care not to drop or damage the RTD unit
during installation. After the entire assembly is complete, the bearing assembly can be put back into service. The assembly
should be inspected for leaks.
5.7 Final Check
Verify the alignment as described in Section 5.3.1. It must be easy to rotate the shaft 360° by hand at the coupling. For elastomer
lined pump assemblies this step should be completed after final installation of the piping. If resistance to hand rotation is observed
the nose gap may need to be reset per Section 10.4 "Setting the Nose Gap".
5.8 Connection to Power Supply
WARNING
 A trained electrician must make the connection to the power supply. Check available main voltage
against the data on the motor rating plate and select the appropriate start-up method. The use of a
motor protection device is strongly recommended.
 An emergency shut off switch should be installed to prevent damage to the personnel and environment
in the event of hazardous pump operation.

MDX [en-US]
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6 Commissioning / Operation
CAUTION
Compliance with the following requirements is of paramount importance. Damage resulting from non-compliance
shall not be covered by the scope of warranty. This manual applies to single stage pumps. Procedures for
multistage pumps should be obtained from the GIW/KSB sales office.
6.1 Commissioning / Return to Service
WARNING
Before starting up the pump make sure that the following requirements are checked and fulfilled:
1) If the pump has been in long term storage (more than 3 months), ensure proper storage procedures were
followed, including instructions for removing the pumps from storage (see contract documents and/or
contact your GIW / KSB representative). Failure to follow proper storage procedures will void your warranty.
See Section 3.2 "Storage Requirements".
2) For elastomer lined pumps ensure that the piping has been installed and the torqueing of the piping bolts
has been completed. For all metal pumps this step may be completed during Step 5.
3) The impeller nose clearance has been properly set.
See Section 10.4 "Setting Impeller Nose Gap" for details.
4) Pump drive train final alignment is complete.
See Section 5.3.1 "Alignment" for details.
5) Final torquing of all bolts has been completed.
See Section 11.1 "General Torque" for details.
6) All electrical and power supply connections are in order, including fuses and overload protection devices.
See Section 5.1 "Safety Regulations" for details.
7) All required auxiliary connections, such as shaft seal water, oil coolers, etc. are made, tested and ready to
function.
See Section 5.4.1 "Auxillary Connection" for details.
8) All safety guards and equipment are in place.
See Section 5.5 "Safety Guards" for details.
9) Any required instrumentation has been properly installed.
See Section 5.6 "Oil Temperature Monitoring" for details on RTD installation.
10) Bearing assembly lubrication is completed.
See Section 6.1.1 "Bearing Lubrication" for details.
11) Shaft seal is ready for operation.
See Section 6.1.2 "Shaft Seal Commissioning" for details.
12) Drive train direction of rotation at the pump is correct.
See Section 6.1.3 "Checking the Direction of Rotation" for details.
13) The pump set is primed.
See Section 6.2.1. "Priming the Pump"
14) The desired operating conditions do not exceed those allowed by the pump.
See Section 6.4 "Operating Limits" for details.
6.1.1 Bearing Lubrication
CAUTION
Pump bearing units are shipped empty of oil. Before starting the pump, fill them to the center of the oil level sight
gauge using the GIW Blue 150 synthetic bearing oil supplied with the unit. For vertical pumps, fill the oil reservoir.
 If locally obtained oil is desired, use an equivalent synthetic or a high quality ISO220 or 320 mineral oil suitable for use
with heavy industrial equipment, anti-friction bearings and oil circulating systems. Such oil typically has high
temperature stability, resistance to oxidation and foaming, and inhibits rust, corrosion, and the formation of deposits.
Oils with EP (Extreme Pressure) additives are not generally recommended. Detailed bearing oil specifications and GIW
Blue replacement oil are available from GIW.