KSB GIW LCC Series User manual

Maintenance Manual
2368.8000/A11-14 G2 (02/20/08) LCC
A KSB Company
x
13-Mar-08
Pump Type: LCC – H200-610.5M AM1
Pump Serial Number: 5012-13012 through 13015
Date: March 13, 2008
Purchaser: Metso Minerals
Purchaser’s Order Number P162737
GIW Sales Order Number: G-150234
Shipped To: Constellation Energy
Include the pump’s serial number when ordering replacement parts.
This manual may not be reproduced without written consent of GIW Industries. Additional copies
may be purchased. Please contact your sales representative for details.
GIW INDUSTRIES, INC. KSB AG KSB S.A.
5000 Wrightsboro Road Bahnhofplatz 1 10/14, rue de la Gare
Grovetown, Georgia 30813 USA D-91257 Pegnitz, GERMANY F-76250 Déville-lès-Rouen, FRANCE
[phone] (0 92 41) 71-0 32 82-32 00
FAX
(
706 855-5151 FA
X
(
0 92 41
)
71-17 91 FA
X
32 82-3290
Slurry Pumps
LCC - Metal LCC - Rubber

LCC
2
Contents
Page
Maintenance Manual 1
1 General 5
2 Safety 5
2.1 Marking of Instructions in the Manual 5
2.2 Personnel Qualification and Training 5
2.3 Non-compliance with Safety Instructions 5
2.4 Safety Awareness 5
2.5 Safety Instructions for the Operator / User 5
2.6 Safety Instructions for Maintenance,
Inspection and Installation 5
2.7 Unauthorized Modification and Manufacture
of Spare Parts 6
2.8 Unauthorized Modes of Operation 6
3 Transport and Interim Storage 6
3.1 Transport 6
3.2 Short Term Storage 6
4 Description of the Product and Accessories 6
4.1 Technical Specification 6
4.2 Designation 7
4.3 Design Details 7
4.3.1 Pump Casing 7
4.3.2 Impeller Form 7
4.3.3 Shaft Seal 7
4.3.4 Bearings 9
4.3.5 Permissible Forces and Moments at the
Pump Nozzles 10
4.3.6 Noise Characteristics 10
4.4 Accessories 10
4.5 Dimensions and Weights 10
5 Installation at Site 10
5.1 Safety Regulations 10
5.2 Foundation 11
5.3 Installing the Pump / Unit 11
5.3.1 Aligning the Pump / Drive Train 11
5.3.2 Place of Installation 11
5.4 Connecting the Piping 11
5.4.1 Auxiliary Connections 12
5.4.2 Safety Guards 12
5.5 Final Check 12
5.6 Connection to Power Supply 12
6 Commissioning, Start-up / Shutdown 12
6.1 Commissioning 12
6.1.1 Lubricants 12
6.1.2 Shaft Seal 13
6.1.3 Priming the Pump and Other Checks 13
6.1.4 Checking the Direction of Rotation 13
6.1.5 Cleaning the Plant Piping 13
6.1.6 Suction Strainer 14
6.1.7 Start-up 14
6.1.8 Shutdown 14
6.2 Operating Limits 14
6.2.1 Temperature of the Medium Handled,
Ambient Temperature, Bearing Temperature14
6.2.2 Switching Frequency 14
6.2.3 Density of the Medium Handled 14
6.3 Shutdown / Storage / Preservation 14
6.3.1 Storage of New Pumps 14
6.3.2 Measures to be taken for Prolonged
Shutdown 14
6.3.3 Storage of Elastomer Linings 15
6.4 Returning to Service after Storage 15
7 Maintenance /Repair 15
7.1 General Instructions 15
7.2 Maintenance / Inspection 15
7.2.1 Supervision of Operation 15
7.2.2 Lubrication and Lubricant Change 15
7.2.2.1 Lubrication 15
7.2.2.2 Grease Quality / Grease Changes 15
7.2.2.3 Oil Changes 16
7.3 Drainage / Disposal 16
7.4 Dismantling 16
7.4.1 Sectional Drawings and Bills of Material 16
7.4.2 Dismantling Procedures Impeller 16
7.5 Reassembly 18
7.5.1 General Instructions 18
7.5.2 Mounting of Bearings 18
7.5.3 Inserting Shaft and Bearings into Housing 18
7.5.4 Installing End Covers and Seals 19
7.5.5 Mounting Shaft Sleeve 19
7.5.6 Mounting Stuffing Box 19
7.5.6.1 Stuffing Box 19
7.5.6.2 Packing (non-expeller) 19
7.5.6.3 Packing (expeller) 19
7.5.7 Mounting the Bearing Assembly to Pedestal 20
7.5.8 Metal Expeller Assembly 20
7.5.9 Mounting Shell 20
7.5.10 Elastomer Lined Wet End 20
7.5.11 Impeller 21
7.5.12 Suction Plate and Liner ( LCC-H only) 21
7.5.13 Axial Adjustment of the Bearing Housing 21
7.5.14 Expeller Running Clearance 21
7.5.15 Tightening Torques 22
7.5.16 Water Purge for Gland Packing 22
7.6 Spare Parts Stock 23
7.6.1 Maintenance Procedures for Maximum
Parts Life 23
7.7 Operational Problems and Solutions 23
8 Trouble Shooting 25
9 Torque Values for Metric Fasteners 26
NOTES
27
10 General Drawing with List of Components 28

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11 Supplements 28
11. 1 Stuffing Box Throat Bushing Option 28
11.2 Underwater Pump Operation with Duo-Cone
Bearing Seals 30
11.3 Duo-Cone Seals 31
11.4 Diverter 33

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Index
Section Page Section Page
Accessories 4.4 ........10
Aligning the Pump / Drive Train 5.3.1 .....11
Bearing Assembly Clamp Bolts 7.5.15 ...22
Bearing Assembly, mounting 7.5.7 .....20
Bearing Housing, Axial Adjustment of 7.5.13 ...21
Bearing, Taper Locknut Assembly Torque 7.5.15 ...22
Bearings 4.3.4 .......9
Bearings, mounting 7.5.2 .....18
Bills of Material 7.4.1 .....16
Casing 4.3.1 .......7
Cavitation / NPSH Performance 7.7 ........23
Check, Final 5.5 ........12
Commissioning 6.1 ........12
Commissioning, Start-up / Shutdown 6 ...........12
Connections, Auxiliary 5.4.1 .....12
Density of the Medium Handled 6.2.3 .....14
Description of the Product and Accessories 4 .............6
Design Details 4.3 ..........7
Dimensions 4.5 ........10
Drainage / Disposal 7.3 ........16
Drawing / List of Components 9 ...........28
Drawings , Sectional 7.4.1 .....16
Elastomer Lined Wet End, assembly 7.5.10 ...20
End Covers and Seals, installation 7.5.4 .....19
Expeller Running Clearance, 7.5.14 ...21
General 1 .............5
Grease Quality / Grease Changes 7.2.2.2 ..15
Guards, 5.4.2 .....12
Impeller Break-Loose Jig 7.4.2 .....16
Impeller Form 4.3.2 .......7
Impeller Lifting Jig 7.4.2 .....16
Impeller, mounting 7.5.11 ...21
Impeller, parts life 7.6.1 .....23
Installation at Site 5 ...........10
Installation, Checks to be Carried out Prior to 5.2 ........11
Installing the Pump / Unit 5.3 ........11
Lubricants 6.1.1 .....12
Lubrication 7.2.2.1 ..15
Lubrication and Lubricant Change 7.2.2 .....15
Maintenance / Inspection 7.2 ........15
Maintenance /Repair 7 ...........15
Maintenance, General Instructions 7.1 ........15
Marking of Instructions in the Manual 2.1 ..........5
Noise Characteristics 4.3.6 .....10
Oil Changes 7.2.2.3 ..16
Operating Conditions of Flow and Head 7.7 ........24
Operating Limits 6.2 ........14
Operation, Supervision of 7.2.1 .....15
Operation, Unauthorized modes 2.8 ..........6
Operational Problems and Solutions 7.7 ........23
Packing the gland 7.5.16 ...22
Personnel Qualification and Training 2.2 ..........5
Piping System Design 7.7 ........24
Piping, Allowable Forces and Moments 4.3.5 .....10
Piping, Cleaning the Plant 6.1.5 .....13
Power Supply, Connection 5.6 ........12
Priming the Pump and Other Checks 6.1.3 .....13
Reassembly , General Instructions 7.5.1 .....18
Reassembly 7.5 ........18
Safety 2 .............5
Safety Awareness 2.4 ..........5
Safety Instructions for the Operator / User 2.5 ..........5
Safety Instructions, for Maintenance 2.6..........5
Safety Instructions, Non-compliance with 2.3 ..........5
Safety Regulations 5.1 ........10
Seal Water Requirements 7.5.16 ...22
Shaft Seal 4.3.3 .......7
Shaft Seal, Commissioning 6.1.2 .....13
Shaft Sleeve, mounting 7.5.5 .....19
Shaft, insertion into Housing 7.5.3 .....18
Shell, mounting 7.5.9 .....20
Shell, parts life 7.6.1 .....23
Shutdown / Storage / Preservation 6.3 ........14
Shutdown 6.1.8 .....14
Shutdown, Prolonged 6.3.2 .....14
Spare Parts Stock 7.6 ........23
Spare Parts, Unauthorized Modification of 2.7 ..........6
Specifications 4.1 ..........6
Start-up Strainer 6.1.6 .....13
Storage of Elastomer Linings 6.3.3 .....15
Storage of New Pumps 6.3.1 .....14
Storage, Returning to Service after 6.4 ........15
Storage, /Short term 3.2 ..........6
Stuffing Box, mounting 7.5.6 .....19
Suction Liner, parts life 7.6.1 .....23
Suction Plate and Liner ( LCC-H only) 7.5.12 ...21
Sump Design 7.7 ........23
Switching Frequency 6.2.2 .....14
Temperature, of Medium Handled, Ambient 6.2.1 .....14
Transport 3.1 ..........6
Transport and Interim Storage 3 .............6
Trouble Shooting 8 ...........25
Wear Problems and Solutions 7.7 ........23
Wear, Parts Life 7.6.1 .....23
Weights 4.5 ........10

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Caution
1 General
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.
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.
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.
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 Marking of Instructions in the Manual
The safety instructions contained in this manual whose non-
observance might cause hazards to persons are specially
marked with the general hazard sign, namely
safety sign in accordance with DIN 4844-W9.
The electrical danger warning sign is
safety sign in accordance with DIN 4844-W8.
The word
Caution
is to introduce safety instructions whose non-observance
may lead to damage to the machine and its functions.
Instructions attached directly to the machine, such as:
xArrow indicating the direction of rotation
xMarking 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.
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:
xFailure of important machine / unit functions
xFailure of prescribed maintenance and servicing
practices
xHazard to persons by electrical, mechanical and
chemical effects
xHazard 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 the Operator / User
xAny hot or cold components that could pose a hazard
must be equipped with a guard by the operator.
xGuards that are fitted to prevent accidental contact with
moving parts (e.g. coupling) must not be removed while
the machine is operating.
xLeakages (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.
xElectrical hazards must be eliminated. (Refer to the
relevant safety regulations applicable to different
countries and / or the local energy supply companies.)
2.6 Safety Instructions for Maintenance, Inspection
and 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.

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Caution
Work on the machine must be carried out only during
standstill. The shutdown procedure described in the manual
for taking the machine out of service must be adhered to
without fail.
Pumps or pump units handling media injurious to health
must be decontaminated.
Immediately following completion of the work, all safety /
protective devices must be re-installed and / or re-activated.
Please observe all instructions set out In the chapter on
“Commissioning” before returning the machine to service.
2.7 Unauthorized Modification and Manufacture of
Spare Parts
Modifications or alterations of the machine are only
permitted after consultation with the manufacturer. Original
spare parts and accessories authorized by the manufacturer
ensure safety. The use of other parts can invalidate any
liability of the manufacturer for damage or warranty.
2.8 Unauthorized Modes of Operation
Any warranty of the operating reliability and safety of the
pump / unit supplied is only valid if the machine is operated
in accordance with its designated use as described in the
following sections. The limits stated in the data sheet must
not be exceeded under any circumstances.
3 Transport and Interim Storage
3.1 Transport
Proper lifting and safety practices must be observed at all
times. Lifting the pump assembly requires extreme care,
since the center of gravity is not located in the physical
center of the unit, but is usually closer to the stuffing box /
shaft seal area.
Never lift by a single point and do not use the pump or motor
shaft as a lift point. Eyebolt locations on the bearing
assembly and motor are intended for lifting those items only
and must not be used to lift the pump assembly.
At least four (4) connections are recommended to stabilize
the load, and they should be as far apart as practical. Avoid
excessive side loads on cast lifting eyes. Note that certain
lift points on the pedestal are intended for use in handling
the pedestal alone and are not necessarily optimum balance
points for the pump assembly.
Always make sure that the unit remains in the horizontal
position during transport and cannot slip out of the transport
suspension arrangement.
If the pump / unit slips out of the suspension
arrangement, it may cause personal injury and
damage to property.
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.
Fig. 3.1-1 Transport of the pump
WARNING: Very top heavy
Fig. 3.1-2 Transport of the complete unit
3.2 Short Term Storage
The pump / unit should be stored in a dry room where the
atmospheric humidity is as constant as possible.
If stored outdoors, the unit and crates must be covered by
waterproof material to avoid any contact with humidity.
All openings of the assembled pump / unit components are
closed and must only be opened when required during
installation.
Protect all stored goods against humidity,
dirt, vermin and unauthorized access!
Short term storage requirements are defined for up to 3
months. For storage exceeding 3 months see Section 6.3 on
long term storage requirements.
4 Description of the Product and
Accessories
4.1 Technical Specification
Centrifugal pump for handling coarse or fine particles from
solids-laden waste water to aggressive slurries of an
abrasive or corrosive nature.
Applications include process pumping and tailings disposal
for mining, dredging and other industrial operations.

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4.2 Designation
LCC-M 300-710.5M C M1
Pump Type l
Hydraulic Type l
Discharge Nozzle DN in mm l
Nominal Impeller Diameter in mm l
Mechanical Size l
Seal Type l
Options l
Material Code l
Hydraulic Type
M ............................................ Metal
R............................................. Elastomer
H............................................. Extra-Heavy Construction
Mechanical (Frame) Size
Seal Type
K ....................................... KE
B ....................................... Throat Bushing
M ....................................... Mechanical Seal
E ....................................... Expeller
Options
O ....................................... Open Shroud Impeller
A ....................................... Oil Lubricated
....................................... Grease Lubricated
T ....................................... Turn Down Impeller
U ....................................... Underwater Bearing Assembly
C ....................................... Elastomer Impeller
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.
4.3.1 Pump Casing
Three standard configurations are available:
1 Hard Metal. Single-wall casing, impeller and suction
liner of high-chrome white iron. Suitable for high-discharge
head, all particle sizes up to maximum sphere passage and
mildly corrosive slurries. Custom materials available for
highly corrosive slurries.
2 Elastomer Lined. Radially split construction with ductile
iron outer casing and molded-elastomer inner liners.
Impeller of high chrome white iron or polyurethane. For
moderate discharge head, fine to medium particles and
highly corrosive slurries.
3 Extra Heavy Hard Metal. Similar to hard metal version,
but with heavier sections and hydraulics suited to the most
severe slurry duties. Two-stage pressure capability.
Available in sizes LCC 150 - 500 and above.
All casings carry 125 pound, ANSI flange bolting patterns.
Adapters for conversion to DIN flanges are available.
Figure 4.3-1 LCC Hard Metal Wet End
Figure 4.3-2 LCC Elastomer-Lined Wet End
Figure 4.3-3 LCC Extra Heavy Hard Metal Wet End
4.3.2 Impeller Form
All standard impellers are 3 vane, double shrouded designs
as seen in figures 4.3-1 through 4.3-3. Open-shrouded and
alternate vane number designs are available in some sizes.
4.3.3 Shaft Seal
All standard pumps use replaceable gland packing in a
stuffing box with connections for flush water or sealing liquid.
Options include throat bushing, slurry duty mechanical seals
or expeller with grease lubricated gland packing.
1 2 3 4 5
35 mm 50 mm 70 mm 100 mm 125 mm

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8
Fig 4.3-4 Gland Packing (non-expeller)
Fig 4.3-5 Typical Expeller Arrangement
Expeller seals are used in pump applications where limited
or no gland flush water is readily available or where it is not
compatible with the process fluid. A second rotating impeller
contained in a separate casing creates a lower pressure at
the stuffing box seal area. This allows the shaft sleeve to be
grease lubricated and run with only enough packing
compression to seal the pump.
Unlike mechanical seals, expellers must be carefully
selected for each application and specific operating
conditions. Expellers require additional driver horsepower,
which must be accounted for during motor selection.
Changes to head, flow, pump speed, process solids or sump
level after the pump has been installed can affect the
functionality of an expeller sealing system.
Correct installation, adjustment and operating procedures
are extremely critical to the proper function and life of these
seals. Extensive testing has shown that the following
guidelines can help keep the expeller system operating
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.
Slurry SG – The Specific Gravity of the slurry should remain
below 1.35.
Solids – Slurries that could deposit scale on pump surfaces
should be avoided.
Flow rate – Stay between 0.5 and 1.3 times the Best
Efficiency Point (QBEP).
Flushing – Solids in the process flow can precipitate out
when the pump stops and build up in the expeller chamber.
Over time, this reduces efficiency and accelerates wear. The
system should always be purged with clear water for at least
15 minutes prior to stopping the pump. Starting the system
on clear water will help the expeller displace solids. 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 see
supplement 11.4.
It is important to operate the expeller pump within the speed
limitations and operating conditions specified in the original
design parameters. Wide variations in flow rate and solids
can allow particles to accumulate in the expeller chamber,
which may result in a plugging or premature component
failure. 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.
Throat Bushing Optio
n

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Fig 4.3-6 Typical Slurry Mechanical Seal
For information on mechanical seals, consult the
manufacturer’s manual.
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 for reference. Note that the suffix can
vary depending on configuration and vendor. Replacement bearings
are available from GIW/KSB.
1) Timken Co. part numbers shown, Koyo is also an approved
supplier.
2) 125 mm taper roller bearing assembled from two single row
bearings. Other sizes are TDO (one piece cup) design.
Bearing Bearings Installed
Assembly Spherical Double row, Taper roller
roller
E Type
Part number
Cone / Cup /
Spacer 1)
Bench
end-play
mm (inch)
35 mm 22209 E 53177 / 53376D
/ X2S53176
0.15
(.006)
50 mm 22212 E 72225C /
72488D /
X1S72225
0.15
(.006)
70 mm 22217 E 9285 / 9220D /
X4S9285
0.18
(.007)
100 mm 22224 E HM926740 /
HM926710CD/
HM92674XA
0.25
(.010)
125 mm
2)
22230 E HH932145 /
HH932110 /
H932145XA
0.20
(.008)
Fig 4.3-7 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.
4.3.6 Noise Characteristics
If running within the normal limits of operation and on clear
liquid, the sound pressure level for the pump alone does
not exceed 80 dB at one meter.
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.
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
between units. For belt driven units, add an additional 2
dB.
4.4 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.
4.5 Dimensions and Weights
Dimensions and weights are listed on the pump
installation plan.
5 Installation at Site
5.1 Safety Regulations
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
Allowable Forces lbs (N) Allowable Moments ft-lbs (N-m)
Flange
Size FXF
YF ZM XM YM Z
2 inch
(50 mm) 2490 (11070) 1980 (8800) 3000 (13340) 2640 (3570) 2640 (3570) 4000 (5420)
3 inch
(75 mm) 2730 (12170) 2170 (9680) 3290 (14670) 2900 (3930) 2900 (3930) 4390 (5960)
4 inch
(100 mm) 2980 (13270) 2370 (10550) 3590 (15990) 3160 (4290) 3160 (4290) 4790 (6500)
6 inch
(150 mm) 3470 (15440) 2760 (12280) 4180 (18610) 3680 (4990) 3680 (4990) 5580 (7570)
8 inch
(200 mm) 3950 (17580) 3140 (13980) 4760 (21190) 4200 (5690) 4200 (5690) 6360 (8620)
10 inch
(250 mm) 4420 (19690) 3520 (15660) 5330 (23730) 4700 (6380) 4700 (6380) 7130 (9670)
12 inch
(300 mm) 4890 (21780) 3890 (17320) 5900 (26240) 5210 (7070) 5210 (7070) 7900 (10710)
D
i
s
c
h
a
r
g
e
P
i
p
e14 inch
(350 mm) 5350 (23830) 4260 (18950) 6450 (28710) 5710 (7740) 5710 (7740) 8650 (11730)
3 inch
(75 mm) 3290 (14670) 2730 (12170) 2170 (9680) 4390 (5960) 2900 (3930) 2900 (3930)
4 inch
(100 mm) 3590 (15990) 2980 (13270) 2370 (10550) 4790 (6500) 3160 (4290) 3160 (4290)
6 inch
(150 mm) 4180 (18610) 3470 (15440) 2760 (12280) 5580 (7570) 3680 (4990) 3680 (4990)
8 inch
(200 mm) 4760 (21190) 3950 (17580) 3140 (13980) 6360 (8620) 4200 (5690) 4200 (5690)
10 inch
(250 mm) 5330 (23730) 4420 (19690) 3520 (15660) 7130 (9670) 4700 (6380) 4700 (6380)
12 inch
(300 mm) 5900 (26240) 4890 (21780) 3890 (17320) 7900 (10710) 5210 (7070) 5210 (7070)
S
u
c
t
i
o
n
P
i
p
e14 inch
(350 mm) 6450 (28710) 5350 (23830) 4260 (18950) 8650 (11730) 5710 (7740) 5710 (7740)

LCC
11
Caution
Caution
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 (e.g. foreman’s
office).
5.2 Foundation
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 Pump / Unit
After placing the base plate on the foundation, it must be
leveled by shimming. Shims should be fitted between the
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
of more than 800mm (30 in.), 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
base plate using low shrinkage grout.
d800
Shim Shim Shim
Foundation bolts
Fig. 5.3-1: Fitting required shims (mm)
5.3.1 Aligning the Pump / Drive Train
All components must be level during
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
Proper alignment must be taken into consideration when
using the 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.
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.
Coupling check 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 as specified in the installation
plan must be observed.
The pump set is correctly aligned if a straight-edge 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 (see Figures 5.3.2 and 5.3.3).
a
ab
b
Gau
g
e
Straight edge
Straight edge
Fig. 5.3-2: Aligning the coupling with the help of a gauge
and a straight-edge
The radial and axial deviation (tolerance) between the two
coupling halves should not exceed 0.1 mm (0.004 inch).
Improper alignment of the unit can cause damage
to both the coupling and the unit itself!
For V-belt installations, the pulleys are correctly aligned if
a straight-edge placed vertically shows a deviation of no
more than 1.0 mm (0.04 in.). Both pulleys must be parallel.
max. 1mm
align
Fig. 5.3-3 Aligning of V-belt pulleys
5.3.2 Place of Installation
The volute casing and the mechanical seal (if
equipped) take on approximately the same
temperature as the pump fluid. The mechanical seal (if
equipped), bearing assembly and bearing housing must
not be insulated.
Take the necessary precautions to avoid burns to
personnel and adjacent equipment.
.
5.4 Connecting the Piping
Never use the pump itself as an
anchorage point for the piping. The
permissible pipeline forces must not be exceeded (see
Section 4.3.5).

LCC
12
Caution
Suction lift lines should be laid with a rising slope towards
the pump and suction head lines with a downward slope
towards the pump. The pipelines should be anchored in
close proximity to the pump and should be connected
without transmitting any stresses or strains. The nominal
diameters of the pipelines should be at least equal to the
nominal diameters of the pump nozzles. It is
recommended to install check and shut-off elements in the
system, depending on the type of plant and pump. It must
be ensured, however, that the pump can still be drained
and dismantled without problems.
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.
Danger of life when toxic or hot media are
handled.
The flange covers on the pump suction and discharge
nozzles must be removed prior to installation in the piping.
5.4.1 Auxiliary Connections
The dimensions and locations of the auxiliary connections
(cooling, heating, sealing liquid, flushing liquid, etc.) are
indicated on the installation plan or piping layout.
These connections are required for proper
functioning of the pump and are therefore
of vital importance!
5.4.2 Safety Guards
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.
5.5 Final Check
Re-check the alignment as described in Section 5.3.
It must be easy to rotate the shaft by hand at the coupling.
5.6 Connection to Power Supply
Atrained electrician must make the connection to the
power supply. Check available mains voltage against the
data on the motor rating plate and select the appropriate
start-up method.
We strongly recommend the use of a motor protection
device.
6 Commissioning, Start-up /
Shutdown
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 GIW/KSB
sales office.
6.1 Commissioning
Before starting up the pump make sure that the following
requirements are checked and fulfilled.
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).
xMake sure the unit is properly connected to the
electric power supply and is equipped with all
protection devices.
xMake sure all auxiliary connections (5.4.1) are
connected and functioning.
xIf the pump has been out of service for a long period
of time, proceed in accordance with Section 6.4.
6.1.1 Lubricants
Grease Lubricated Bearings
Grease lubricated bearings are packed with grease at the
factory. They should be re-lubricated after the initial 50
hours of operation, and at regular intervals thereafter. See
Section 7.2.2.2 for grease lubrication instructions.
If shaft speeds exceed those in the table below, the
bearing housing temperature should be monitored during
commissioning and additional grease added if it exceeds
100oC (210oF), or if bearings are noisy . In some cases
where external cooling of the housing is poor, it may be
necessary to stop and allow the bearings to cool several
times during this break-in period.
Some lubricant may be expelled from the labyrinth oil
seals upon startup. This is normal and will stop once the
excess grease has been purged.
Oil-lubricated bearings
Units may be shipped without oil from the factory. Fill with
the supplied GIW Blue 150 oil to the center of the sight
gauge.
Before starting the pump, verify that the bearing assembly
is correctly filled to the center of the oil level sight gauge.
Do not overfill. Factory filled units contain GIW Blue ISO
150 synthetic bearing oil. This is available as GIW part
number 690-9090P-01-B150P. Otherwise, use an
equivalent synthetic or a high quality ISO220 mineral oil
suitable for use with heavy industrial equipment, anti-
friction bearings and oil circulating systems. Such oil
typically have high temperature stability, resistance to
oxidation and foaming, and inhibit rust, corrosion, and the
formation of deposits. Oils with EP additives are not
recommended.
Typical oil operating temperatures for GIW bearing
assemblies will run from 125 to 185°F (50 to 85°C),
depending on the pump size, speed and ambient
conditions. For oil temperatures above 185°F (85°C) or
for severe load conditions, a high quality synthetic
Bearing
Assembly
Shaft Speed (rpm), monitor
commissioning temperature if over:
35mm 2300
50mm 1800
70mm 1400
100mm 1000
125mm 750
Caution

LCC
13
Caution
lubricant should be used. Contact your GIW/KSB
representative for a recommendation. At higher speeds, or
in hotter ambient conditions, temperatures can rise to
210°F (100°C). Slightly higher temperatures may be seen
for a brief period during the breaking in of new bearings.
The unit should be shut down immediately if temperatures
rise to 250°F (120°C).
Bearing Assembly Approximate Oil Capacity
liters (quarts)
35 mm 0.75 ( 0.75 )
50 mm 1.0 ( 1.0 )
70 mm 1.75 ( 2.0 )
100 mm 3.0 ( 3.25 )
125 mm 6.0 ( 6.5 )
Do not overfill the bearing assembly. The capacities listed
above are approximate. When filling the bearing housing,
the oil level must be at the centerline of the oil level sight
glass when the shaft is not turning. This is the ”cold level”
and will change as the pump runs and the oil becomes
suspended in the bearings.
The constant oil leveler is no longer available. It is not
recommended for use since it can increase oil level
when the pump is running and cause leaks at bearing
seals.
Oil level with
pump stopped
Fill plug
Oil level
sight glass
Drain plug
Underwater Operation
Bearing assemblies for use underwater should be
completely filled with oil and slightly pressurized by an oil
recirculation and filtering system. As a result, their
capacities will be several times greater than shown above
and a thinner oil will be required. Depending upon the
water temperature at the location at which the pumps are
operating, the ISO viscosity grade should be altered as
follows for mineral oil-based lubricants:
Water Temperature ISO Viscosity Grade
0 to 20 oC (32 to 70 oF) 100
20 to 30 oC (70 to 85 oF) 150
over 30 oC ( over 85 oF) 200
GIW Blue oil may be used for all the above temperatures
For more information on Underwater Bearing Assemblies
see section 11.2 and 11.3
6.1.2 Shaft Seal Packing
Prior to commissioning, the gland packing supplied with
the pump must be adjusted as described in Section
7.5.16. Preformed packing rings sets from GIW / KSB are
recommend. For alternate brands, refer to packing
manufacturer’s instructions regarding installation and use
(see Section 2.7).
For gland flush supply, use suitable non-aggressive clean
water not liable to form deposits and not containing
suspended solids. Hardness should average 5 with a
ph>8. It should be conditioned and neutral with regard to
mechanical corrosion.
An Inlet Temperature of 10 to 30oC (50 to 85 oF) should
produce a maximum Outlet Temperature 45oC (115 oF)
when the gland is properly adjusted.
Running the pump dry will result in
increased wear on the gland packing and
shaft protecting sleeve or failure of the mechanical seal.
Mechanical Seals
Mechanical seals are precision devices, which require
special care for their proper operation. If pump is equipped
with a mechanical seal, the instruction manual for the seal
should be consulted for special storage, startup and
maintenance requirements.
Mechanical seals require safety checks
prior to start-up such as removing seal
assembly fixtures, checking axial alignment, etc. Refer to
the mechanical seal operating manual for all required
safety checks.
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
The impeller must rotate in the direction
indicated by the arrow on the pump
casing. This must be verified by briefly
running the motor with the coupling or belt drive
disconnected. If the motor runs in the wrong direction of
rotation, have it corrected and verify direction of rotation
before reconnecting coupling or belts. If a Variable
Frequency Drive (VFD) or other controller is used, it is
recommended to permanently disable REVERSE and
BRAKE function during controller set up.
If motive power is applied to the pump, and it is run in the
wrong direction of rotation, even momentarily, the impeller
may unscrew causing extensive damage to the entire unit.
This is especially important during initial start up as the
impeller may not be fully torqued onto the pump shaft.
6.1.5 Cleaning the Plant Piping
The cleaning operation mode and duration for
flushing and pickling service must be matched to
the casing and seal materials used.
Fig. 6.1.1: Oil fill, drain and level
Caution
Caution

LCC
14
Caution
Caution
6.1.6 Suction Strainer
If a suction strainer has been fitted to protect the pumps
against dirt and/or to retain contamination from the plant;
the strainer’s contamination level must be monitored by
measuring the differential pressure to ensure adequate
inlet pressure for the pump.
6.1.7 Start-up
Before starting the pump ensure that the
shut-off element in the suction line is fully
open. The pump may be started up against a closed
discharge-side swing check valve or shut-off element.
Only after the pump has reached full rotational speed
should the shut-off be opened slowly and adjusted to
comply with the duty point. When starting up against an
open discharge-side shut-off element, take the resulting
increase in input power into account.
Prolonged operation against a closed shut-off
element is not permitted. Danger of steam
generation and explosion!
Once the operating temperature has
been reached and / or in the event of
leakages, switch off the unit and re-
tighten all bolts. Check the coupling alignment as
described in Section 5.3.1 and re-align, if necessary.
6.1.8 Shutdown
Under no circumstances should the pipe system be
equipped with a check valve or other device that can
rapidly decelerate the flow rate.
Switch off the drive, making sure that the unit runs
smoothly down to a complete stop. Variable
Frequency Drive (VFD) and other controllers must
not use any braking function to slow the pump.
Diesel power trains should disengage the clutch and
allow the pump to coast to a stop.
Close any auxiliary connections. Pressurized
bearing lubrication systems must remain running
until all rotation has stopped. If the any part of the
system uses a cooling liquid supply, turn that off only
after the pump has cooled down. Where liquid filled
shaft seals are used, consult seal maintenance
manual for specific shutdown procedures.
In the event of shutdown where a
significant static discharge head exists
in the system, the impeller can begin to run
backwards as the flow reverses in the pipeline. This
creates a positive torque on the shaft so the impeller
connection will not unscrew. Until the flow stops, do
not close any main line valves. A change in fluid
velocity can create a negative torque on the impeller
and unscrew it from the shaft. This can damage wet
end pump parts as well as bearings, seals and other
components
Where temperatures may drop below freezing, the
pump and system must be drained or otherwise
protected against freezing.
6.2 Operating Limits
The pump’s / unit’s application limits regarding
pressure, temperature and speed are stated on the
data sheet and must be strictly adhered to. If a data sheet
is not available, contact your GIW/KSB representative.
6.2.1 Temperature of the Medium Handled, Ambient
Temperature, Bearing Temperature
Do not operate the pump at temperatures exceeding those
specified on the data sheet or the nameplate unless the
written permission of the manufacturer has been obtained.
Damage resulting from disregarding this warning will not
be covered by the manufacturer’s warranty.
Bearing temperatures, as described in Section 7.2.1, must
be observed. Excessive bearing temperature could
indicate misalignment or other technical problem.
6.2.2 Switching Frequency
To prevent high temperature increases in the motor and
excessive loads on the pump, coupling, motor, seals and
bearings, the switching frequency should not exceed the
following number of start-ups per hour (h):
6.2.3 Density of the Medium Handled
The power input of the pump will increase in proportion to
the density of the medium handled. To avoid overloading
of the motor, pump and coupling, the density of the
medium must comply with the data specified on the
purchase order.
6.3 Shutdown / Storage / Preservation
Each GIW / KSB pump leaves the factory carefully
assembled. If commissioning is to take place some time
after delivery, we recommend that the following measures
be taken for pump storage exceeding 3 months.
6.3.1 Storage of New Pumps
xMaximum protection for up to 12 months, if the pump
is properly stored indoors.
xStore the pump in a dry location
xRotate the pump rotor by hand once a month.
xFollow manufacture’s instructions for mechanical
seals.
xSee requirements for rubber liner storage below.
6.3.2 Measures to be taken for Prolonged Shutdown
1 The pump remains installed; operation check run
In order to make sure that the pump is always ready
for instant start-up and to prevent the formation of
deposits within the pump and the pump intake area,
start up the pump set regularly once a month or once
every 3 months for a short time (approx. 5 minutes)
during prolonged shutdown periods. Prior to an
Motor rating max. switchings / hr
up to 12kW (16hp) 25
up to 100kW (135hp) 20
more than 100kW (135hp) 10
Caution

LCC
15
Caution
Caution
operation check run ensure that there is sufficient
liquid available for operating the pump.
2 The pump is dismantled and stored
Before putting the pump into storage carry out all
checks specified in Sections 7.1 to 7.4. It is advisable
to close the nozzles (for ex. with plastic caps or
similar).
6.3.3 Storage of Elastomer Linings
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 .
Properly stored elastomer parts will retain their properties
for about two years for gum rubber, or five years for
neoprene or urethane. The parts should be periodically
inspected 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.
6.4 Returning to Service after Storage
Before returning the pump to service carry out all checks
and maintenance work specified in Sections 7.1 and 7.2.
The instructions given in the sections on
“Commissioning” (6.1) and “Operating Limits” (6.2)
must be observed.
Upon completion of the work, all safety-related and
protective equipment must be properly refitted
and/or reactivated before starting the pump set.
7 Maintenance /Repair
7.1 General Instructions
The LCC pump range is an international product and has
been designed, in most respects, to the METRIC system
of units using metric components. All fasteners are metric
and will require metric tooling. All seals are metric
including oil seals, O-rings and stuffing box packing.
Two important exceptions: 1) The suction and discharge
flange bolting patterns are to the American (ANSI)
standard, however, flange adapting spools are available.
2) The drive end bearing is an inch based taper roller
bearing.
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.
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.
7.2 Maintenance / Inspection
7.2.1 Supervision of Operation
The pump should run quietly and free
from vibrations at all times. Unusual
noise or vibration should be investigated
and corrected immediately.
Operational procedures that may cause system
water hammer must be avoided. Sudden and
catastrophic failure of pump casing and plates may
result.
When running the pump against a closed discharge-side
shut-off element for a short period, the permissible
pressure and temperature values must not be exceeded.
Prolonged operation against a closed shut-off
element is not permitted. Danger of steam
generation and explosion!
Verify correct oil level as described in Section 6.1.1.
The gland packing (if the pump is fitted with one) should
drip slightly during operation. The gland should only be
gently tightened.
Any stand-by pumps installed should be switched on and
off again once a week to keep them operational. Attention
should be paid to the correct functioning of the auxiliary
connections.
If the flexible coupling elements begin to
show signs of wear, they should be
replaced.
7.2.2 Lubrication and Lubricant Change
7.2.2.1 Lubrication
The rolling element bearings are lubricated with grease or
GIW Synthetic Blue 150. The lubricant change intervals
as well as the required quantity and quality are specified
below.
Under severe operating conditions, high ambient
temperature, high humidity, dust laden air, aggressive
industrial atmosphere, etc. the intervals for checking,
replenishing and replacing the lubricant should be
shortened.
7.2.2.2 Grease Quality / Grease Changes
The bearings are packed with high-quality lithium-soap
grease. Under normal operating conditions the fill should
be replenished every 1500 hours by an injection roughly
equal to one half of the amount originally used to pack the
bearings. After 20000 operating hours or 2.5 years the
bearings should be checked, then cleaned and re-
lubricated if required.
For this purpose use high-quality lithium-soap grease, free
of resin and acid, not liable to crumble and with good rust-
preventive characteristics. The type of grease required for
temperatures above 0 degrees Fahrenheit is Cheveron
Ultra-Duty Grease 2 (Lithium Base) or equivalent. For

LCC
16
temperatures below 0 degrees Fahrenheit, use Cheveron
Avi-Motive Grease W or equivalent. The bearing cavities
should be fully packed with grease.
After adding grease, some excess may be expelled from
the labyrinth oil seals. This is normal and will stop once
the excess grease has been purged.
7.2.2.3 Oil Changes
The first oil change should be carried out after 300
operating hours, the following ones after every 3000 hours
or when it appears or is suspected of being dirty or
contaminated.
See section 6.1.1 for oil specifications and capacities.
7.3 Drainage / Disposal
If the pump was used for handling liquids
posing health hazards, see to it that there
is no risk to persons or the environment when draining the
medium. All relevant laws, local codes, and safety
procedures must be heeded. If required, wear safety
clothing and a protective mask.
If the media handled by the pumps leaves residues which
might lead to corrosion when coming into contact with
atmospheric humidity, or which might ignite when coming
into contact with oxygen, the unit must be flushed
thoroughly and neutralized.
The flushing liquid used and any liquid residues in the
pump must be properly collected and disposed of without
posing any risk to persons or the environment.
7.4 Dismantling
Before dismantling, secure the pump so as to
make sure it cannot be switched on accidentally.
The shut-off elements in the suction and discharge
nozzles must be closed. The pump must have cooled
down to ambient temperature, it must be drained and its
pressure must be 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
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 relevant sectional drawing. 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.
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.
When lifting a plate that contains two swivel hoist
rings, do not allow the angle between the lines of
tension from the rings exceed 120°. This could cause the
hoist rings to fail.
Impeller Break-Loose Jig
Rotate the impeller until the tip of one blade is facing the
pump discharge. Insert the jig through the eye of the
impeller and attach to trailing edge of blade facing
discharge. Rotate the shaft in the direction opposite to
normal, using the pump pulley or a spanner wrench.
NOTE: For ease of impeller removal, the shaft threads
should be heavily coated with anti-seize compound during
re-assembly. Also, two aramid paper gaskets should be
used between the shaft sleeve and the impeller.
IMPELLER
BREAK LOOSE JIG
Figure 7.4-1 Impeller Break-Loose Jig
Impeller Lifting Jig
Bearing Approximate Grease Capacity
Assembly Spherical
Roller Bearing
Taper
Roller Bearing
35mm 15 ml (1/2 oz) 20 ml (3/4 oz)
50mm 20 ml (3/4 oz) 40 ml (1.5 oz)
70mm 30 ml (1 oz) 90 ml (3 oz)
100mm 90 ml (3 oz) 190 ml (6 oz)
125mm 140 ml (5 oz) 280 ml (10 oz)
Caution

LCC
17
For impeller removal or installation, grasp the impeller at
the suction eye as shown in Figure 7.4-2. The impeller
can be leveled by turning the adjusting bolt which bears
against the impeller nose. This is especially useful during
re-installation. For impeller removal ensure that the lifting
line is tight prior to thread disengagement.
Do not remove, lift, move or re-install impeller
without properly using a recommended impeller
lifting jig.
Figure 7.4-2 Impeller Lifting Jig
Shell
It is recommended that at least two lift points be used
when moving any pump shell. This permits greater safety
and control of the component. Where applicable, GIW
pump shells are supplied with cast lifting eyes for this
purpose. Note that if the chain hook does not fit the lifting
eye, an appropriate clevis should be installed. Another
acceptable lifting point is a chain secured around the
discharge flange, being careful not to damage the bolt
flanges.
Elastomer-Lined Wet End
Most liners fit snug into the casings. Two threaded push-
off holes at 180 degrees are provided in the casings to aid
in removal. If reuse of the liners is anticipated, care must
be taken to push the liners out evenly to avoid bending of
the steel backing plate.
Expeller Assembly:
- for 2x3 and 3x4 LCC-M Pumps
After supporting the pump shell, remove the nuts from all
four of the studs (902.10) which hold the shell in place.
Dismount the shell and the expeller plate (16-4) together,
allowing the expeller casing to rest on and be supported
by the 4 studs.
Go to the “removing expeller” section below.
- for LCC-R, LCC-H, and all other LCC-M Pumps
After supporting the pump shell, remove the nuts from all
six of the studs (902.10), which hold the shell in place.
This excludes hex head bolts at the 3 & 9 o’clock positions
which mount the expeller plate to the shell (901.14) and
expeller casing to the pedestal (901.13). Dismount the
shell and the expeller plate (16-4) together.
If not removed in the above manner, the expeller
plate may fall without warning after the shell is
removed.
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.
Cartridge Bearing Assembly
Drain the oil (if applicable) by removing the drain plug on
the bottom of the housing.
Remove the flingers (if any) and bearing housing end
covers. Care should be taken with the Inpro oil seals,
which should not be removed from the end covers unless
they have been damaged and are in need of replacement.
Inspect the seals, gaskets, and o-rings, and discard any
that appear worn or broken.
The locknut and lock washer that clamp the drive side
bearing should also be removed. One tab of the lock
washer will be bent into a recess on the lock ring and must
be bent back to allow the lock nut to be unscrewed.
The shaft and bearings (which are pressed onto the shaft)
may then be removed as a unit from the drive end of the
housing. Horizontal disassembly is acceptable when
proper support is given to the shaft to prevent its
contacting and marring any of the finished surfaces of the
shaft or bearing housing bore. Care should be taken to
avoid damaging the grease retaining ring (part 63-7,
grease lubricated) or spacer ring (part 45-4, oil lubricated)
that will come out on the shaft between the two bearings.
The bearings are hot when installed on the shaft, and fit
tight. It is difficult to remove them from the shaft
undamaged, and they should be removed only if a bearing
needs to be replaced. Bearings are normally removed by
heating, which should be done quickly to prevent heating
of the shaft as well. Flame cutting of the outer race and
careful grinding of the inner race may occasionally be
required; however, care must be taken to avoid damaging
the shaft, especially in the oil seal area.

LCC
18
Caution
Caution
7.5 Reassembly
7.5.1 General Instructions
The pump should be reassembled in accordance with the
rules of sound engineering practice. Use the sectional
drawing and bill of material for guidance.
See section 7.4.2 for safety precautions regarding lifting
plates with swivel hoist rings.
Before assembly, thoroughly clean all
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.
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
mounting aids or anti-adhesives other than those
described are required, please contact the sealing material
manufacturer.
7.5.2 Mounting of Bearings
The grease retaining ring (63-7, for
grease lubrication) or spacer ring (45-4,
for oil lubrication) must be placed on the
shaft between the bearings, and in the proper orientation,
before both bearings are mounted. Once the bearings are
mounted, they cannot be removed without risk of damage.
The grease ring is essential in protecting the taper bearing
from loss of lubrication in the event of high loadings.
Failure to install the ring may result in significantly reduced
bearing life.
The bearings are press fitted to the shaft and should be
heated to 120 oC (250 oF) by a suitable bearing heater, oil
bath, or other even heating device prior to mounting.
Flame heating is not recommended. When mounting, it is
important that the bearings are seated fully against the
abutting shaft shoulder.
In mounting the taper roller bearing, it is important to heat
the outer race (or cup) along with the inner races (or
cones) to ensure proper seating against the inner spacer
required by this preset clearance type bearing.
Before the taper roller bearing has cooled on the shaft,
use the lock nut without lock washer to fully seat the
bearing against the shaft shoulder. (The lock washer must
be left out during this step to prevent damage)
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
washer and allow the locknut to back off
during operation.
Do not back off the locknut any amount
after tightening in an attempt to set the
bearing clearances. The LCC taper
bearing has an 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.
See Section 7.2.2.2 for grease lubrication requirements
Figure 7.5-1 LCC Drive End Taper Roller Bearing
7.5.3 Inserting Shaft and Bearings into Housing
After insuring the bearing outer diameters and housing
bores are thoroughly clean, insert the shaft with bearings
and grease (or spacer) ring into the housing from the drive
end. It will be necessary to align the grease (or spacer)
ring 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
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.
Caution
Caution
Caution

LCC
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. If possible, use a hand operated arbor
press instead of a hydraulic press to improve control of the
pressing operation. You will be overcoming a light
interference fit and may shear off a portion of the outer
diameter o-ring, however, this is normal and indicates a
secure fit.
Slide end covers with gaskets and Inpro seals over the
shaft at each end, again making certain that the
contaminant expulsion port and lubrication return trough
are located at the bottom. Use O-Ring lubricant, Parker
O-Lube or Parker Super-O-Lube to lubricate the inner
diameter o-rings against the shaft. Take special care
when running the seal over the shaft keyway to avoid
cutting the o-ring. If necessary, lightly file the keyway
edges to avoid this problem.
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 of the parts. Any larger gap may indicate that
the taper roller bearing is not fully seated into the housing.
For oil lubrication see Section 7.2.2
Figure 7.5-2 VBX Inpro Seal for LCC
7.5.5 Mounting Shaft Sleeve
In mounting the shaft sleeve, do not allow anti-seize
compound to come in contact with any of the axial faces
of the shaft sleeve, including the impeller contacting face
or the face in contact with the shaft shoulder. For ease of
removal, a light coating of anti-seize compound should be
applied to the inner diameter of the shaft sleeve.
Lubrication at any of shaft sleeve or shaft shoulder
faces may result in overloading and breakage of
the shaft.
In many cases, there will be an o-ring which must be
placed on the shaft first. As the shaft sleeve is pushed into
position, this o-ring should be completely forced into the
shaft sleeve recess.
If a non-split lantern ring or throat bushing is being used, it
should be placed onto the shaft sleeve at this time.
Figure 7.5-3 Standard LCC Shaft Sleeve Arrangement
7.5.6 Mounting Stuffing Box
7.5.6.1 Stuffing Box
The stuffing box should be mounted so that the sealing
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
access. Note that the small stuffing boxes have a single
inlet while the larger sizes have a second port that can be
used for additional flow or have a pipe plug installed.
Location of the stuffing box is provided by a close
clearance fit with the pedestal. No additional centering
operation is required.
In some cases, a separate stuffing box wear plate may be
provided. Apply RTV to the back of the wear plate before
bolting it to the stuffing box.
See Figure 4.3-4 for typical stuffing box arrangement.
7.5.6.2 Packing (non-expeller)
The packing arrangement consists of a lead ring, followed
by a standard lantern ring, and then three more rings of
packing (two rings for 70mm shaft).The packing should be
well coated with water resistant grease during assembly.
See figure 4.3-4.
7.5.6.3 Packing (expeller)
As of 2004, the static seal for the expeller has been
modified. The forward ring of packing and the standard
lantern ring have been replaced with a low flow throat
bushing. The throat bushing is followed by a ring of
packing, a special lantern ring, and then a second ring of
packing.. All rings of packing should be well coated with
water resistant grease during assembly. See figure 4.3-5
There is an additional rear tap on the stuffing box for
grease lubrication of the packing, allowing the primary
(forward) taps to be reserved for intermittent flush water,
when needed. When the water purge port is not utilized, a
pipe plug should be used to seal the port opening.

LCC
20
7.5.7 Mounting the Bearing Assembly to Pedestal
After mounting the stuffing box (or mechanical seal
adapter) loosely onto the pedestal plate, and screwing the
adjusting screw (909) with nut (924) an appropriate length
into the pedestal, the cartridge bearing assembly may be
placed onto the pedestal saddle. Note that the slotted tab
on the housing must be inserted between the adjusting
screw shoulder and the adjusting nut.
The pedestal and bearing housing saddles should be
clean, dry, and free from oil or grease. If corrosion of the
saddles is a problem, apply a thin film of preservative.
Special care must then be taken in the axial adjustment
procedure to ensure that no movement may occur. (See
the section on Axial Adjustment of Bearing Housing.)
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.
Before mounting the expeller (23-15) a 0.5 mm (0.020
inch) aramid gasket (400.31) is placed between the shaft
sleeve and the expeller to prevent galling and ensure ease
of removal. The gasket should be installed dry, without
grease.
After mounting the expeller, which is a close sliding fit to
the shaft, adjust the bearing assembly towards the drive
end until the expeller just begins to rub on the expeller
casing. Then move it back towards the pump end approx.
1.0 mm (0.4 inch). This is a preliminary adjustment. Final
adjustment will be made after wet end assembly is
complete.
Mount the expeller plate (16-4) at the same time the shell
or casing is mounted by inserting the studs into the shell
or casing and allowing the expeller plate to rest on and be
supported by the studs.
If attempt is made to mount the expeller plate
without the support of the shell or casing studs, it
will not be properly supported and may fall without
warning.
See Figure 4.3-5 for typical expeller arrangement.
- for LCC-R, LCC-H, and all other LCC-M Pumps
Mount the expeller casing (10-7) to the pedestal using two
hex head bolts (901.13) at the 3 & 9 o’clock positions with
the bolt heads on the expeller casing side.
Before mounting the expeller (23-15) a 0.5 mm (0.020
inch) aramid gasket (400.31) is placed between the shaft
sleeve and the expeller to prevent galling and ensure ease
of removal. The gasket should be installed dry, without
grease.
After mounting the expeller, which is a close sliding fit to
the shaft, adjust the bearing assembly towards the drive
end until the expeller just begins to rub on the expeller
casing. Then move it back towards the pump end approx.
1.0 mm (0.4 inch). This is a preliminary adjustment. Final
adjustment will be made after wet end assembly is
complete.
Mount the expeller plate (16-4) to the shell using two hex
head bolts (901.14) at the 3 & 9 o’clock positions. Mount
the expeller plate and shell to the expeller casing and
pedestal by inserting studs into the remaining stud
positions. Hex head bolts at the 3 & 9 o’clock positions
should not be removed or replaced with studs.
If attempt is made to mount the expeller plate
without the support of the shell, it will not be
properly supported and may fall without warning.
See Figure 4.3-5 for typical expeller arrangement.
7.5.9 Mounting Shell
The alignment of the pump shell with the mechanical end
is obtained through a rabbet fit machined into the
pedestal. For the best wear and efficiency performance, it
is essential that the shell be fully seated in this fit.
Ensure that the proper gasket is fitted between the shell
and pedestal before installing.
In the case of the elastomer lined LCC-R pump, the liner
itself forms the seal. See below for additional instructions.
7.5.10 Elastomer Lined Wet End
Firmly seat the liners into the metal casings using a large
rubber mallet if necessary. To seat the suction side liner,
use a wooden brace and large C-clamps, or lay the liner,
flange side up, on a wooden brace and lower the metal
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
to lubricate the liners since they can
cause degradation of the elastomer.
Before assembling the casing halves together, check the
fit of the liners in the casing to ensure that they are seated
correctly, especially in the suction, hub, and discharge
flange areas. Clearance allowing for limited readjustment
of parts has been provided in the holes through which the
liner studs protrude.
When bolting the casings together, ensure that the liners
remain well aligned with each other on their outer
perimeter, especially in the discharge area. Some bulge
may occur at the seam on the discharge flange. This may
be removed, and the sealing surface restored to flatness
by lightly buffing with a coarse grade sand paper or
grinding stone. If desired, rubber gaskets may be applied
at both the suction and discharge flanges, although this is
typically not necessary.
Some bulging may also occur inside the casing between
liners. This is normal and does not affect performance.
Caution