KSB LCV Installation instructions

Installation/Operating Manual
2017.01 LCV [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

LCV [en-US]
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Legal Information/Copyright
Installation/Operating Manual LCV
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 10
3.2.4Removal from Storage 11
3.3Recommended Lifting 12
4Description 13
4.1Technical Specification 13
4.2Designation 13
4.3Design Features 13
4.4Noise Characteristics 14
4.5Accessories 14
4.6Dimensions and Weights 14
4.7Forces and Moments at Nozzles 14
5Installation at Site 15
5.1Safety Regulations 15
5.2Foundation 15
5.3Installing the Baseplate and Pump 15
5.3.1Aligning the Pump / Drive Train for Horizontal Pump
Application 15
5.3.2Place of Installation 16
5.4Connecting the Piping 16
5.4.1Auxiliary Connections 16
5.5Safety Guards 17
5.6Oil Temperature Monitoring 17
5.7Final Check 17
5.8Connection to Power Supply 17
6Commissioning / Operation 18
6.1Commissioning / Return to Service 18
6.1.1Bearing Lubrication 19
6.1.2Shaft Seal Commissioning 19
6.1.3Checking the Direction of Rotation 19
6.1.4Cleaning the Plant Piping 19
6.1.5Suction Strainer 19
6.2Start-up 20
6.2.1Priming the Pump 20
6.3Shutdown 21
6.3.1Measures to be taken for Prolonged Shutdown 21
6.4Operating Limits 21
6.4.1Temperature Limits 21
6.4.2Switching Frequency 22
6.4.3Density of the Medium Handled 22
6.4.4ZW Pump Additional Limits 22
7Maintenance 23
7.1Supervision of Operation 23
7.2Drainage / Disposal 23
7.3Lubrication and Lubricant Change 23
7.4Procedures for Maximum Parts Life 24
7.5Operational Problems and Solutions 24
8Mechanical End 26
8.1Mechanical End Overview 26
8.2Mechanical End Disassembly 27
8.3Mechanical End Assembly 27
8.3.1Mounting the Bearings 28
8.3.2Back to Back Thrust Bearing Installation 28
8.3.3Face to Face Thrust Bearing Installation 29
8.3.4Installing End Covers and Seals 30
8.4Bearing Assembly Mounting 30
9Shaft Seal 31
9.1Seal Plate 31
9.1.1Seal Plate Assembly (LCV Only) 31
10Wet End 32
10.1Wet End Overview 32
10.2Wet End Disassembly 32
10.2.1Impeller Removal 32
10.2.2Impeller Break-Loose Device 32
10.2.3Impeller Removal with Impeller Lifting Device 33
10.2.4Casing Removal 33
10.3Wet End Assembly 33
10.3.1Mounting the Shaft Sleeve 33
10.3.2Mounting the Casing 33
10.3.3Impeller Installation 34
10.4Setting the Nose Gap 34
10.4.1Nose Gap Adjustment (Frame Size 1 & 2) 34
10.4.2Nose Gap Adjustment (Frame Size 3 & 4) 35
11Tooling 36
11.1Torque Requirements 36
11.2Spare Parts Stock 37
12Troubleshooting 38
14Notes 40

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Index
Section Page Section Page
Accessories 14
Alignment 15
Assembly Safety 7
Assembly, Mechanical End 27
Assembly, Wet End 33
Auxiliary Connections 16
Baseplate 15
Bearing Assembly Mounting 30
Bearing Installation 28
Bearing Lubrication, Commissioning 19
Casing 32
Casing Installation 33
Casing Removal 33
Cavitation / NPSH Performance 24
Commissioning 18
Commissioning / Return to Service 18
Commissioning, Bearing Lubrication 19
Density of the Medium Handled 22
Dimensions 14
Direction of Rotation 19
Disassembly Safety 7
Disassembly, Mechanical End 27
Disassembly, Wet End 32
Drainage / Disposal 23
End Covers and Seals, Installation 30
Foundation 15
Impeller 32
Impeller Installation 34
Impeller Removal 32
Impeller Removal, Break-Loose Device 32
Impeller Removal, Lifting Device 33
Impeller, Parts Life 24
Inspection, Safety 7
Installation 15
Installation, Location 16
Installation, Safety 7
Lifting 12
Lubricant Change 23
Maintenance Equipment 36
Maintenance, Safety 7
Mechanical End 26
Mechanical End Assembly 27
Mechanical End Disassembly 27
Mounting the Bearings 28
Noise Characteristics 14
Nose Gap Adjustment 34
Oil Temperature Monitoring 17
Operating Conditions of Flow and Head 25
Operating Limits 21
Operating Limits, ZW Pumps 22
Operation 18
Operation, Unauthorized Modes 7
Operational Problems and Solutions 24
Parts Life 24
Personnel 6
Piping System Design 24
Piping, Allowable Forces and Moments 14
Piping, Cleaning 19
Piping, Connecting 16
Power Supply 17
Priming the Pump 20
Pump Casing, Parts Life 24
Pump Description 13
Pump Design Features 13
Pump Designation 13
Pump Specification 13
RTD Installation 17
Safety Awareness 7
Safety Guards 17
Safety Markings 6
Safety, Final Check 17
Safety, Non-compliance 7
Safety, Operators 7
Safety, Regulations 15
Safety, Transport & Handling 9
Seal Plate 31
Seal Plate Assembly (LCV Only) 31
Shaft Seal 31
Shaft Seal, Commissioning 19
Shaft Sleeve, Mounting 33
Shutdown 21
Shutdown, Prolonged 21
Spare Parts Stock 37
Spare Parts, Unauthorized Modification 7
Start-up 20
Storage Requirements 9
Suction Liner, Parts Life 24
Suction Strainer 19
Sump Design 24
Switching Frequency 22
Temperature Limits 21
Thrust Bearing Installation (Back to Back) 28
Thrust Bearing Installation (Face to Face) 29
Tooling 36
Torque Requirements 36
Transport, Storage & Handling 9
Troubleshooting 38
Wear Problems and Solutions 24
Weights 14
Wet End 32
Wet End Assembly 33
Wet End Disassembly 32

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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.
 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.
 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.
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.
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.

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Pump Part Pump Part
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
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
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.
 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.

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3.3 Recommended Lifting
WARNING
Actual safe lifting method will vary with pump configuration and type of lifting equipment
Vertical Lifting
Horizontal Lifting

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4 Description
4.1 Technical Specification
This pump range is an international product and has been designed, in most respects, to the Metric system of units using
metric components. All sealing elements and fasteners are Metric and will require metric tooling. Please consult your
arrangement drawings and bills-of-material for details concerning your equipment.
Two important exceptions:
1) The suction and discharge flange bolting patterns are to the American National Standards Institute (ANSI) standard,
however, flange adapting spools are available.
2) The drive end bearing is an inch based taper roller bearing.
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.
4.2 Designation
Example Designation: LCV-M80-300.3T-1OB M1
Pump Type
Hydraulic Type
Discharge Nozzle (mm)
Nominal Impeller Diameter (mm)
Mechanical Size
Seal Type
Cantilever Length
Options
Motor Mount
Material Code
Hydraulic Type
M Metal
Mechanical (Frame) Size
1 35 mm
2 50 mm
3 70 mm
4 100 mm
5 125 mm
Seal Type
S Seal Plate
T Throttle Seal
Cantilever Length
1 900 mm
2 1200 mm
3 1500 mm
4 1800 mm
5 2100 mm
Options
O Open Shroud
Impeller
C Closed Shroud
Impeller
Motor Mount
A Small
B Large
Material Code
M1 Metal
MC2 Metal / Chemical
Resistant
Nominal Flange and Impeller Diameters
Designation Discharge Suction Impelle
r
mm inch mm inch mm inch
LCV 50 - 230 50 2 80 3 225 9
LCV 80 - 300 80 3 100 4 310 12
LCV 100 - 400 100 4 150 6 395 16
LCV 150 - 500 150 6 200 8 500 20
LCV 200 - 610 200 8 250 10 610 24
LCV 250 - 660 250 10 300 12 660 26
LCV 300 - 710 300 12 350 14 710 28
For additional information please contact your GIW / KSB representative.
4.3 Design Features
Vertical, end suction, modified volute casing pump with three-vane impeller for large solids passage.

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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.
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.
4.7 Forces and Moments at Nozzles
Suction piping is normally not used in vertical pump applications. However, if a suction extension is used, the inlet end must be
located a minimum of 1.5 pipe diameters above the bottom of the sump and no closer than 300mm (12").
Discharge flange loads are limited to the weight of the discharge pipe section supplied with the pump by GIW. Any additional
pipe loads or moments must be compensated for by the system pipe supports.
For additional information please contact your GIW / KSB representative.

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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

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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.
 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
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.
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.
1
2

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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.

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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.

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6.1.1 Bearing Lubrication
 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.
 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 100 °C (210 °F), 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.
 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.
 Use high-quality lithium-soap grease, free of resin and acid, not liable to crumble and with good rust-preventive
characteristics.
Size Shaft Speed (RPM)
Grease
Replenishment
Interval (hours)
A
pproximate Grease Capacity
Drive Side Pump Side
mL oz mL oz
LCV Frame 1 *1800 600 30 1.0 40 1.4
LCV Frame 2 *1400 1000 50 1.7 90 3.0
LCV Frame 3 *1000 1500 125 4.2 190 6.4
LCV Frame 4 *750 1500 200 6.7 280 9.5
ZW 40-190
Monitor
Commission
Temperature
1000 30 1.0 40 1.4
ZW 50-350 3000 80 2.7 80 2.7
ZW 65-290 3000 80 2.7 80 2.7
ZW 100-390 3000 80 2.7 80 2.7
ZW 125-405 3000 80 2.7 80 2.7
ZW 150-480 2000 90 3.0 140 4.7
*Monitor commission temperature if exceeded
6.1.2 Shaft Seal Commissioning
Ensure that the seal plate is aligned correctly with the shaft. Adjust if necessary.
6.1.3 Checking the Direction of Rotation
CAUTION
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.
The impeller must rotate in the correct direction of rotation. 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.
6.1.4 Cleaning the Plant Piping
WARNING
Cleaning operations for flushing and pickling service must be matched to the casing and seal materials used.
Any chemicals or high temperatures used must be compatible with all pump parts.
6.1.5 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 so as to ensure adequate inlet pressure for the
pump.

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6.2 Start-up
WARNING
Start-up, shutdown, filling and draining procedures must be designed to prevent any possibility of negative
torque being experienced on the pump shaft. Negative torque can cause the impeller to unscrew, leading to
severe damage throughout the rotating assembly and drive train. In particular, the following practices must be
avoided:
1) Any flow through the idle pump, in any direction, in excess of 5% of the normal operating flow rate before
the impeller has been tightened by running under normal loads. This includes flow due to filling or draining
of the system and/or flow caused by the equalization of different levels between the sump and discharge
line after the opening of any valves in the piping.
2) Any attempt to restrict the flow after shutdown, by either manual or automatic systems, until the pump
comes to a complete standstill.
3) Any braking or re-energizing of the drive train after shutdown, until the system has reached a complete
static condition.
Prolonged operation at zero or low flow, typically due to closed valve or unintended pipeline blockage, is not
permitted. Danger of steam generation and explosion.
Start-up and shutdown procedures must be designed to prevent any possibility of water hammer. Water hammer
can place excessive loads on the piping, resulting in damage to the pump flanges. The pressure waves
generated by water hammer can also cause damage to the pressure containing components of the pump, the
mechanical end and/or the mechanical seal.
CAUTION
During the initial commissioning, once the pump and bearing assembly stabilize at normal operating
temperature, or in the event of system leaks, stop the unit and re-tighten all bolts. Check the coupling alignment
and re-align if necessary.
 The pump may be started up against a closed discharge shut-off element. Once the pump has reached full rotational
speed, open the discharge valve slowly and adjusted to the duty point.
 When starting up against an open discharge-side shut-off element, take the resulting increase in input power
requirements into account.
 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 V-Belt alignment as described in Section 5.3.1 “Aligning the Pump / Drive Train” and re-align if
necessary.
6.2.1 Priming the Pump
WARNING
The pump should never be run dry and air intake must be minimized using proper sump design. May result in
excess temperatures and escape of medium into the atmosphere due to shaft seal failure.
Before start-up, the pump and the tank must be vented and primed with the liquid to be pumped. The shut-off element in the
suction line must be fully open.
Minimal Submergence for Priming
Size
Axial height above centerline of the
pump casing Size
A
xial height above centerline of the
pump casing
mm inch mm inch
LCV 50-230 210 8.25 LCV 200-610 280 11.00
LCV 80-300 215 8.50 LCV 250-660 315 12.25
LCV 100-400 230 9.06 LCV 300-700 350 13.75
LCV 150-500 255 10.00 ZW 200 7.90