SISA – Office & Plant of Dijon

13-15, Boulevard Eiffel – 21604 Longvic Cedex

Phone : +33.3.80.38.33.00 / Fax : +33.3.80.38.33.66

DOCUMENT FRONT SHEET

CUSTOMER TECHNIP FMC
USER MIDOR
PROJECT LPG TO DETHANIZER PUMP
PURCHASE ORDER No. 25440053
ITEM NUMBER 12-P-53A/B
SERIAL No. D871850-1A/B

DOCUMENT TITLE
PUMP OPERATION AND MAINTENANCE
MANUAL

SUNDYNE DOC REF D1850-1-IOM DOC REV 0

CUSTOMER DOC REF SHEET NB 1/96

CUSTOMER REVIEW STATUS / DECAL

VENDOR DOCUMENT REVIEW

1 REVISE AND RESUBMIT

PROJ.: MIDOR REFlNERY EXPANSION
OWNER: MIDDLE EAST OIL REFlNERY (MIDOR) TO BE ISSUED AS FINAL PROVIDED
2
COMMENTS ARE INCORPORATED
MATERIAL REQUISITION No. 3 NO COMMENT – FINAL ISSUE

2544 MR 0 9 1 0 R 0 3 4 FOR INFORMATION ONLY

ITEM: 12-P-53A/B
SR Doc. CODE: A 5015 / A 5016
MB - Nov 11, 2020
PURCHASE OROER N.: 2544A0053

0 For approval Nicolas Billery Denis Marinello Denis Marinello 03/11/2020

REV ISSUE STATUS PREPARED CHECKED APPROVED DATE
 Installation, Operation
& Maintenance Manual

Sundyne Pumps

Model:
LMV-311

SA-07-11-25, Rev A
Oct 2018
SA-07-11-25, Rev Orig Mar 2009
 Copyright

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means,
electronic, mechanical, photocopying, recording or otherwise without the prior permission of Sundyne Corporation.
© 2009 Sundyne Corporation

Warranty

Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the date of being placed in service (but not to exceed eighteen
(18) months after the date of shipment) that the equipment at the time of shipment will be free from defects of design, material and workmanship.
If any defects or malperformance occur during the warranty period, Sundyne’s sole obligation shall be limited to alteration, repair or replacement
at Sundyne’s expense, F.O.B. Factory, of parts or equipment, which upon return to Sundyne and upon Sundyne’s examination prove to be
defective. Equipment and accessories not manufactured by Sundyne are warranted only to the extent of and by the original manufacturers’
warranty. Sundyne shall not be liable for damage or wear to equipment caused by abnormal conditions, vibration, failure to properly prime or to
operate equipment without flow or caused by corrosives, abrasives or foreign objects. THE FOREGOING WARRANTY IS EXCLUSIVE AND
IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no event shall Sundyne be liable for consequential or incidental
damages

http://www.sundyne.com
 Revisions

March 2009 Add seal configurations / misc. updates

October 2018 Correct double seal diagram

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SA-07-11-25, Rev A Oct 2018
 Contents
Contents.............................................. ii
Storing Your Pump Short-Term ......... 8

INTRODUCTION .................................. 1 Storing Your Pump Long-Term .......... 8

Sundyne Centrifugal Pumps ............... 1 Suction and Discharge Piping ............ 9

Text Symbols........................................... 1 Seal Environmental Control System10

Equipment and Safety Precautions .. 2 Liquid Buffer System .......................... 10

Wearing Personal Protective
Equipment ............................................. 2 Mounting Vertical Units Without
Using Forklifts ....................................... 2 Stands ..................................................... 10
Ensuring Electrical Safety ................... 2
Testing Equipment ............................... 2 Mounting Vertical Units with Stands
Using Chemicals .................................. 3 (LMV) ....................................................... 11
Protection from Falling ........................ 3
Preventative Machine Guards ............ 3 Base Mounted (BMP) Units ............... 11

Pre-Commission Checklist .................. 3 Driver and Coupling ............................ 11

Familiarizing Yourself with the Pump 3
Flexible Coupling for LMV Units
Driver Instructions ................................ 3
Without a Vertical Stand..................... 12
Verifying Auxiliaries .............................. 3
Installing a Seal Environmental
Control System ..................................... 4 LUBE SYSTEM .................................. 13
Checking Driver Rotation .................... 4
Piping Connections .............................. 4 Lube System.......................................... 13

Start-Up Procedures.............................. 5 Gearbox Heat Exchanger ................... 13

Review start-up checklist. ................... 5 Oil Manifolds ....................................... 13
Pressurizing the Fluid Loop ................ 5 Remote Heat Exchanger ................... 14
Servicing the Gearbox ......................... 5
Gearbox Sump ...................................... 14
Auxiliary Lube Pump ............................ 5
Setting the Valves ................................ 5 SundGard Oil Filter ............................ 14
Control Checklist ................................... 5 Main Lube Pump and Lube Oil
Verifying Operating Conditions .......... 5 Priming Kit ............................................. 15
Adjusting the Cooling Flow ................. 5
Oil Pressure ........................................... 15
Installation and Start-Up Checklist ... 6
START UP ......................................... 16
INSTALLATION ................................... 8
Start-Up Procedures............................ 16
Inspection................................................. 8

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Controlling the Pump During Startup Steam Bushing Assemblies (If
................................................................... 17 Throat Bushing Does Not Apply) ..... 58
Single Operation ................................. 17
Parallel Operation............................... 17 Procedure for Checking the High-
Speed Shaft Endplay ........................... 62
OPERATION & CONTROL ................ 18
TROUBLESHOOTING ....................... 64
Operation of Sundyne Pumps .......... 18
Suction Conditions ............................. 18 Gearbox & Pump Diagnostics .......... 64
Minimum Flow Conditions ................. 18
Entrained Gases ................................. 18 Pump Mechanical Seal Diagnostics 66
System Head Curve ........................... 18
Parallel Operation............................... 19 SPECIFICATIONS ............................. 68

MAINTENANCE ................................. 20 Falk Steelflex Type Coupling

Specifications ....................................... 68
Disassembly of LMV-311.................... 20
Falk Double Gear Type Coupling
Inspection, Cleaning and Repair...... 31 Specifications ....................................... 68
Inspecting All Bearings ...................... 31
High-Speed Shaft ............................... 31 Falk Double Gear Type-Vertical
Gearbox Mechanical Seal ................. 31 Specifications ....................................... 69
Shaft Sleeve ........................................ 32
Thomas Type DBZ Coupling
Bearing and Shaft Clearances .......... 32 Specifications ....................................... 69

Reassembly of the LMV-311.............. 33 Thomas SN Spacer Type Vertical &

Horizontal Coupling Specifications 70
Gearbox Seal Assembly ..................... 41
Metastream Coupling Specifications
Steps for Single Seal Only ................. 42 ................................................................... 70

Steps for Dual Pressurized (Double Gearbox Lube Oil Specifications ..... 71
Seal) Only ............................................... 44
Gearbox Parts List ............................... 73
Steps for Dual Unpressurized
(Tandem) Seal Only ............................. 47 Gearbox Replacement Parts ............. 74

Steps for Single Seal with Isolation Torque Specifications ......................... 75

Bushing Only......................................... 50
Mechanical Seals ................................. 76
Steps for Single Seal with Steam
Pump Disassembly Replacement
Bushing Only......................................... 53
Parts......................................................... 78
Throat Bushing Option for Single
Pumps Parts List .................................. 79
Seal and Tandem Seal Only .............. 56
Single Seal Arrangement and Parts 80
Continuation for Single, Dual
Pressurized (Double), Tandem, and Double Seal Arrangement and Parts
................................................................... 81
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SA-07-11-25, Rev A Oct 2018
Tandem Seal Arrangement and Parts Pump Casing and Seal Housing
................................................................... 82 (Exploded View).................................... 86

Separator Arrangements.................... 83 Gaskets ................................................... 87

Pump and Gearbox Cross Section

INDEX ................................................ 88
(Single Seal Arrangement)................. 84

LMV-311 Gearbox (Exploded View) . 85

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 Instruction and Operation Manual

INTRODUCTION
Sundyne Centrifugal Pumps
Sundyne API pumps provide high-energy This manual presents installation, servicing,
performance and competitive efficiencies in a troubleshooting, maintenance and spare parts
compact unit that is easy to maintain. Sundyne information for the latest configuration of
pumps are single stage that utilize an integral Sundyne centrifugal pumps.
gearbox. Designed to increase the pressure of a
continuous flow of fluid by applying centrifugal Note: Parenthetical numbers included in the
action, Sundyne pumps are most commonly text correspond to item numbers on the
used in HPI, CPI, and Boiler Feed applications. illustrated figures. The correct spare
Commonly applied in refineries, petrochemical part can be ordered for any generation
plants, and power generation plants, Sundyne pump by referencing the item and serial
pumps are used in high-head, low-to-medium numbers.
flow processes.

Text Symbols
The following symbols may be found in the text
RECOMMENDED: Text accompanied by
of this manual.
this symbol indicates recommended
They have the following meanings: usage.
WARNING: Text accompanied by this
symbol indicates that failure to follow
directions could result in bodily harm or REMINDER: Text accompanied by this
death. symbol indicates a reminder to perform
an action.

ELECTRICAL HAZARD: Text EQUIPMENT USE ALERT: Text

accompanied by this symbol indicates accompanied by this symbol indicates
that failure to follow directions could result that failure to follow directions could result
in electrical damage to equipment or in damage to equipment.
electrical shock.

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 Instruction and Operation Manual

Equipment and Safety Precautions

Sundyne Corporation manufactures centrifugal • Hearing protection is strongly
pumps to exacting International Quality recommended at all times when noise
Management System Standards (ISO 9001) as levels exceed 85 dB during an eight (8.0)
certified and audited by Lloyd’s Register Quality hour period.
Assurance Limited. Genuine parts and
accessories are specifically designed and tested Note: Chemical resistant gloves must be used
for use with these products to ensure continued if chemicals are utilized (refer to Using
product quality and performance. Sundyne Chemicals for additional information).
cannot test all parts and accessories sourced
from other vendors; incorrect design and/or Note: A dust mask respirator must be worn if
fabrication of such parts and accessories may chemicals have warning labels
adversely affect the performance and safety regarding fumes, dust, or mists.
features of these products. Failure to properly
select, install or use authorized Sundyne pump When using more than one piece of protective
parts and accessories is considered misuse and equipment, consider their compatibility. For
damage or failure caused by misuse is not example, safety glasses will not interfere with
covered by Sundyne’s warranty. Additionally, hearing protection equipment. Be sure to clean
modification of Sundyne products or removal of all pieces of personal protective equipment
original components may impair the safety of immediately after each use.
these products and their effective operation.
Using Forklifts
CAUTION Any persons operating a forklift must have an
Sundyne pumps may handle hazardous, active recognized operator license.
flammable, and/or toxic fluids. Proper personal Note: Before initializing forklift operation,
protective equipment should be worn. verify that the lift is in a safe operating
Precautions must be taken to prevent physical position.
injury. Pumpage must be handled and disposed
of in accordance with applicable environmental
regulations. Ensuring Electrical Safety
All electrical sources must be powered-off
before installation, service, or repair of
Note: Safety procedures must be applied equipment occurs.
prior to any installation, maintenance,
or repair of a Sundyne pump. Failure to Note: Sundyne recommends that a Lock-
follow safety precautions may lead to out/Tag-out program be followed prior
injury! to altering the equipment. Locks or
tags must be provided to warn
Wearing Personal Protective
employees that equipment is
temporarily unavailable.
Equipment Once all work has been completed, the person
To ensure safety, protective equipment must be installing the lock or tag must remove it
worn at all times when installing, performing according to company procedure.
maintenance, or repairing equipment. The
Testing Equipment
following safety recommendations must be
adhered to for optimum safety:
Prior to performing a test on newly installed,
• Safety glasses, with the minimum maintained, or repaired equipment; all personnel
requirement of side shields, must be worn in the immediate area must be warned.
at all times.
Note: Follow company procedures prior to
• Steel-toed shoes must be worn when
equipment testing at all times.
lifting equipment greater than 15 pounds
(7 kg) or if pallet jacks or forklifts are
operated.
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 Instruction and Operation Manual

Using Chemicals Preventative Machine Guards

Any chemicals to be used must be accompanied Preventative guards must remain in place on all
by a relevant material safety data sheet (MSDS), equipment.
in accordance with government legislation. If
applicable, use chemical proof gloves. Note: Only remove the guards while
performing maintenance or repair.
Note: An eye wash station (or equivalent)
should be available in the event of Replace the guards immediately after working
injury. If any hazardous or flammable on the equipment and prior to start up.
chemicals pass through the equipment,
a complete decontamination of the
equipment is required. EXPLOSION/FIRE HAZARD
Protection from Falling Note: Never use an acetylene torch, open
flame, or heat to attempt to remove
Fall protection and associated preventative parts that have seized together in
measures are required when working on Sundyne equipment. Any residual
equipment located six feet or higher from the process gas or liquid that is flammable
ground. can result in an explosion or fire with
potential for serious injury or death.
Note: Follow company fall prevention
procedures prior to working on
equipment.

Pre-Commission Checklist

Familiarizing Yourself with the Pump Verifying Auxiliaries

Before servicing and starting up the Sundyne Before start up, verify that the following
pump, carefully review all information on the auxiliaries are met:
product, including:
• Check the utility connections
• Specification sheets
• Verify that the auxiliary piping conforms
• Outline drawings to Sundyne standards, as indicated in
the detailed specifications
• Performance curves
• Verify all switch and instrument
• Instruction and related manuals connections
• System P&ID/Process Flow Diagram • Verify that all switch and instrument
(Clients equipment) settings are set to normal operating
• Control system and operational standards
philosophy/narrative (Client) • Calibrate all measurement equipment,
Familiarize yourself with the pump configuration such as flow meters, ampere meters,
before starting and operating the pump. and pressure meters, etc.

Driver Instructions
Carefully follow all installation and starting
instructions provided by the driver manufacturer.
This information is included in the final data
package.

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 Instruction and Operation Manual

Installing a Seal Environmental Control Piping Connections

System Verify that the following bolted or threaded
connections are tight:
• Install a system to control the seal
environment. See outline drawing and seal • Pump flange bolts
housing port identification schematic found
in the "Seal Environmental Control System" • Seal environment piping and port
section of this manual. connections

• Verify that port 1 is properly drained. • Cooling water connections to heat

exchanger (if applicable)
• If required, install vent piping overhead to
ensure that the environment operates under • Gearbox oil drain plug
normal conditions. For more information, • Pump case drain plug
contact Sundyne Corporation.
• Port 1 must be open to drain
Checking Driver Rotation • Is a check valve in the discharge line?
If the driver is coupled, un-couple; then verify • Note: A start-up bypass line upstream of
that the direction of the driver rotates in the the check valve is recommended
same direction as the arrow stamped or cast on whenever feasible.
the pump casing.

If the driver is splined, check the direction of the

motor fan.

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 Instruction and Operation Manual

Start-Up Procedures

Review start-up checklist. Note: Sundyne recommends that gearbox

lube oil be changed at least every six
Pressurizing the Fluid Loop
months.

Pressurize the double seal buffer loop or For requirement information about priming the
external seal flush, if applicable, prior to lube oil system, refer to the start-up section in
admitting fluid into the pump casing. this manual.

Servicing the Gearbox Auxiliary Lube Pump

Fill the gearbox with lube oil up to a quarter inch If your pump includes an auxiliary lubrication
(¼) or 6 mm from the top of the oil level sight pump, unlock the electrical circuit and move it to
glass. the “hand” position. Check for oil leaks and
recheck the oil level.
Note: Prior to using lube oil, verify that it
conforms to acceptable lube oil
specification standards. Refer to the
Setting the Valves
SPECIFICATIONS section in this To set the pump to the designated operating
manual for more information. point, start the pump with the suction valve in
the open position while throttling the discharge
Under normal operation, the lube oil level will be valve.
about a quarter inch lower than when off. Some
foaming may occur at the top of the site glass
during operation.

Control Checklist

Verifying Operating Conditions The status of these conditions will significantly

alter performance of the pump if they are not in
Verify the following parameters against the accordance with the specification sheet.
specifications on the specification sheet:
Check with your Sundyne representative if the
• Suction pressure operation conditions of your pump must run
• Suction temperature under different parameters than indicated by the
specifications on the specification sheet.
• Discharge pressure
• Total head Adjusting the Cooling Flow
• Flow rate If your model pump includes an installed heat
exchanger for the gearbox, adjust the cooling
• Power consumption flow to keep the temperature of the gearbox
sump at 140°-160°F (60°-71°C). Maximum
• Specific gravity
recommended temperature is 180°F (82°C).
• Viscosity
• Net Positive Suction Head (NPSH)

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 Instruction and Operation Manual

Installation and Start-Up Checklist

Note: Lock out all switch gears, including main driver, auxiliary lubrication system and instrumentation
before working on this equipment.
This checklist is NOT intended to be inclusive. You must read and follow: instruction manuals, outline
drawings, specification sheets and curves for this equipment during installation, commissioning, and
operation. Please call with any questions or comments. Be sure to have the unit serial number that is
imprinted on the gearbox nameplate, and request “Sundyne Field Service”.
 Is all the information underlined above readily available?
 Are the following bolted/threaded connections tight?
o Pump flange bolts?
o Seal environment piping and port connections?
o Cooling water connections to heat exchanger(s)(if applicable)?
o Gearbox oil drain plug?
o Pump case drain plug?
 There are two types of connections between the motor and gearbox; a splined shaft or a
coupling. For splined connections, the splined shaft must be lubricated with the supplied spline
grease and the two o-rings installed prior to mounting the motor. It is recommended that the input
shaft be rotated by hand prior to mounting the motor. If the unit has a coupling, be sure the
coupling gap is correct and bolting between coupling halves is tight. This instruction manual
contains coupling set-up information. It is not necessary to align the coupling for run-out or
flatness as this is controlled by the rabbet fits on the gearbox and coupling adaptor.
 Is a check valve installed in the discharge line?
 Is Port 1 open to atmosphere or piped to safety drain or flare or vent header? (Back pressure
must not exceed 5 psig).
Note: A drip leg must be used if the Port 1 connection rises from the seal housing.
 Are all other seal system ports identified and connected according to the outline drawings?
 Is gearbox filled to within ¼” (6.35mm) of the top of the sight glass with the approved oil and the
breather fitting installed? Oil capacity is 7 quarts (6.6 liters). Is the needle valve on the gearbox
pressure gauge open? Removal of the vent plug below the fill/vent fitting will speed filling.
 Has the oil filter, heat exchanger, and related piping been filled with oil (primed)?
 Do process conditions, suction pressure, suction temperature, discharge header pressure, and
specific gravity agree with specification sheet information? DO NOT test the pump on water
unless it is designed for water. Check with your representative or Sundyne Corporation if you
must test on a different fluid than shown on the specification sheet.
 If you have auxiliary lubrication pump, unlock the electrical circuit and start it in the “hand”
position. Check for oil leaks and recheck the oil level. If the process suction pressure exceeds
460 psig (32.3 kg/cm2g), the auxiliary lube pump should be running prior to and anytime the
suction is pressurized.
 Prior to starting the unit, have you opened the suction valve fully and discharge throttled to allow
design flow, typically 40-50% open? Check the control valve to be sure it is functional. Inspect the
case drain, ports, and flanges for leaks. Has the pump been vented through Port 6? Open both
supply and return valves supplying cooling water to the gearbox heat exchanger. Check suction
pressure to be sure it agrees with the specification sheet.

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 Instruction and Operation Manual

 Unlock the main driver circuit and bump the motor. Rotation is CCW as viewed from the top end
of the motor. Is rotation correct? Once rotation is verified, run motor for 1 second on, 20 seconds
off. Do this several times until gearbox oil pressure gauge shows pressure, then start the main
driver. Oil pressure will be between 15-60 psig (1.1-4.2 kg/cm2g) depending on the type of
bearings in the gearbox. After priming the lube oil pump, bumping the motor is not required.
 If pressure control is being used, throttle the discharge valve immediately after start-up. Does the
discharge pressure agree with the specification sheet? If flow control is being used, adjust the
valve until flow agrees with the design value listed on the specification sheet.
 Once the gearbox oil temperature has stabilized, adjust cooling water supply until the oil
temperature is 140-160°F (60-71°C) on units equipped with heat exchangers. Maximum
recommended temperature is 180°F (82°C).
 Listen for any unusual noises or pressure fluctuations.
Note: If you have any questions or concerns about these procedures or the information supplied,
please call your representative or Sundyne Corporation.

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 Instruction and Operation Manual

INSTALLATION
Inspection
Immediately inspect your Sundyne product upon Note: The input shaft on the pump may not
receipt of the equipment. Check for any turn freely due to seal drag and speed
damage, which may have occurred during increasing gear meshes. If the input
shipment. Notify the carrier and Sundyne shaft does turn freely, and if rotation is
immediately if damage is evident. “not smooth,” damage may have
occurred during shipping.

Storing Your Pump Short-Term

If your Sundyne pump is not to be installed seal ports. Ensure that the shipping covers be
immediately, protect it from exposure to kept securely in place.
moisture and dust. Do not remove the factory
installed shipping covers for casing flanges and Note: Observe the storage instructions
provided by the driver manufacturer.

Storing Your Pump Long-Term

In addition to the precautions in the short-term Note: Any inspection fees are the sole
section above, additional precautions are responsibility of the purchaser.
required for long-term storage.
Factors which affect the quality of a Sundyne
If your Sundyne pump will not be operated for a pump, when stored, are:
period of time exceeding six months from the
date of shipment, long-term storage conditions • Humidity
must be met to ensure minimum corrosion • Temperature
damage to the gearbox and fluid-end
components. • Surrounding chemicals
Note: Sundyne does not accept liability for Long-term storage methods must prevent
equipment damaged during the storage damaging conditions from making contact with
period. Sundyne does not guarantee the internal components of the equipment. When
the quality of equipment during and the equipment is stored in strong chemical
after the storage period. environments or near salt water, protection must
occur immediately upon receipt of the
To ensure the original quality of the Sundyne equipment.
pump after storage, all components must be
inspected by an authorized Sundyne service Recommended Long-Term Storage
engineer. Components that are not Procedures
manufactured by Sundyne (except mechanical Sundyne recommends that you do the following
seals) must be inspected by its own to prevent damage to your pump during long-
manufacturer. term storage:

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 Instruction and Operation Manual

1. Store your pump only in an indoor, climate 4. Use desiccant bags.

controlled building. These conditions will
maintain constant temperature and humidity. Note: Because long-term storage of
equipment is of a highly critical nature,
2. Perform inert gas purging of component it is recommended that Sundyne be
internals. contacted to provide more details on
3. Ensure oil flooding of gearbox internals. the above procedures.

Suction and Discharge Piping

Please adhere to the following best practices for 4. Sundyne recommends using a straight pipe
installing and maintaining suction and discharge assembly of at least three times the length
piping: of the pipe diameter.
1. Install a suction strainer (12 mesh - .062" or Note: Carefully select the size of pipe and
1.66mm opening) and clean the suction line fittings to be installed so that friction
prior to starting the pump. This procedure losses will remain low.
will protect the impeller from damage by mill
scale, welding slag, or other foreign particles 5. Never use a suction pipe that is smaller in
during initial startup. diameter than the pump suction inlet.

Note: Sundyne Recommends installation of a 6. Sundyne recommends installation of a

differential pressure instrument across discharge check valve to prevent reverse
strainer to indicate strainer condition. rotation.
7. Use block valves (both suction and
2. When installing piping to the pump, ensure
discharge) when isolating the pump during
that all piping is supported independently
shutdown. This practice will minimize
from the pump.
process leakage and prevent possible
3. All piping must always line up with the pump reverse rotation from pump back-flow.
flanges.
8. It is recommended that suction and
Note: Never use force to position piping into discharge pressure gauges be installed on
place at the flanged suction and any pump that is not flow controlled. If no
discharge connection locations. Failure flow measuring device is installed there is no
to have piping properly aligned may way to determine accurately where on its
impose excessive strains on the unit. curve the pump is operating.

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 Instruction and Operation Manual

Seal Environmental Control System

A seal environmental control system may be Ensure that the specified seal environmental
required depending upon the pump seal control system is properly installed and that the
arrangement and application. ports are open (or plugged) as indicated in
Figure 1.
Always maintain the pump seal environment as
detailed on the specification sheet that
accompanies each unit.
Note: Port 1 must always be open so that it is
Note: For most applications, a standard free to drain.
control system can be obtained from
the factory.
Figure 1. Seal Housing Port Identification

Liquid Buffer System

For double liquid seals and tandem liquid seals, Buffer flow should be 0.5 to 3 gpm (2 to 12
a liquid buffer system is used. Introduce the liters/min) with an inlet temperature of 60o to
buffer liquid into port 7, which will flow through 120oF (16o to 49oC), and inlet pressure as
the seal cavity, and out from port 2. indicated on the pump specification sheet. The
liquid must be clean to 5 microns.

Mounting Vertical Units Without Stands

For all vertical units without stands, a mounting should be installed in the foundation as shown
base is recommended. The pump should be on the installation drawing. The length of the
mounted on a rigid foundation, secured in bolts should be sufficient to extend at least ½-
position by one-inch diameter bolts. The bolts inch above the nut.

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 Instruction and Operation Manual

Mounting Vertical Units with Stands (LMV)

Grouting of the base plate is required for all channels that are to be filled with grout through
vertical stand units. The top of the stand (driver the access holes. The nuts on the foundation
mounting surface) should be leveled by bolts should not be tightened until the grout has
shimming under the base prior to grouting the set for at least 48 hours.

Base Mounted (BMP) Units

Grouting of the base plate is required on all BMP be allowed to set for at least 48 hours before
units. The base plate should be leveled prior to tightening foundation bolts.
grouting. After grout has been applied, it must

Driver and Coupling

Drivers are normally shipped separately from the Also available are solid shaft drivers coupled to
gearbox and pump. When a splined the gearbox with a flexible coupling. Drivers are
interconnecting shaft is supplied, this shaft must to be installed and maintained in accordance
be lubricated at each end with one tube (5cc) of with the manufacturer’s instructions.
anti-fretting compound (Sundyne Part Number
MP01AA10).

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 Instruction and Operation Manual

Flexible Coupling for LMV Units Without a Vertical Stand

Note: Lock out the driver starting switch Figure 3. Dimension Y
before working on the coupling.
When installing flexible couplings, use those
supplied by Sundyne to ensure tolerance of
parallel and angular misalignment, and axial end
float. Use flexible disc couplings or gear type
couplings if not using those supplied by
Sundyne. Coupling installation for turbine drivers
is identical to that for motors.
The gearbox coupling hub is normally mounted
at the factory. The driver coupling hub is
mounted on all motors and turbines shipped
4. Scribe the shaft to show dimension Y.
directly from Sundyne.
5. Ensure that the coupling hub bore, keyways,
Driver Coupling is Not Mounted
and shaft are clean and free from burrs.
If your product is received without the driver Also determine that the key fits in the
coupling hub mounted, use the following keyways.
procedure when installing Falk or Thomas
couplings: 6. Heat the hub in an oil bath or oven to
approximately 250oF (121oC),or more if
1. Measure the distance from the top surface necessary, so that the hub will slide onto
of the gearbox hub, to the datum face of the the motor shaft.
driver adapter. This measurement is
referred to as dimension”X”. 7. Position the hub at the scribed line on the
shaft.
Figure 2. Dimension X
8. Tighten the hub key set screw.
Note: Before the hub is installed onto the
flexible disk couplings, verify that the
coupling bolts and washers can be
assembled (Figure 4) from the motor
side of the hub when installed. If these
pieces do not assemble, insert short
bolts with bevel washers into the hub
2. Determine the end gap (the distance flange before fitting them onto the shaft.
between each coupling hub) for the size of Figure 4. Assembly of Coupling Bolts and
coupling provided. Refer to the Coupling Washers
Specifications tables in the Specifications
section of this manual for specific
measurements.
3. Subtract the end gap value from dimension
X to determine the distance from the driver
datum face to the coupling hub face. This
value is referred to as dimension “Y.”

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LUBE SYSTEM
Lube System
The internal lube oil system engineered for The lube pump intakes oil from the sump and
Sundyne pumps consist of four major passes it internally to an externally mounted
components. They are: manifold. The oil is then passed through the
heat exchanger, the filter, and back into the
• Gearbox sump gearbox. Once the oil is passed through the
• Main lube pump bearings, it then drains back into the sump.
• Oil heat exchanger
• Oil filter

Gearbox Heat Exchanger

The standard heat exchanger is a shell and tube Oil Manifolds
water-cooled type. For optimum performance,
the following conditions must be met. There are two standard oil manifold
configurations, MA01AA78 for units without heat
• Cool water must be provided to the tube exchangers and MA01AA79 for units with heat
side at a maximum pressure of 150 psig exchangers. For units purchased prior to 1991,
(11 kg/cm2)(103.5Kpag). the standard manifold is MA01AA01.
• Coolant flow must be controlled to Figure 5. Heat Exchanger Manifolds
maintain a gearbox sump temperature MA01AA78 (left), MA01AA79 (center),
between 140°F and 160°F (60°to 71°C). MA01AA01 (right).
Maximum recommended temperature is
180°F (82°C).
The optional air-cooled heat exchanger should
be controlled to maintain the same gearbox
sump temperatures as above.
Mount the heat exchanger lower than the oil
filter to prevent air pockets in the lube oil lines at
start up. Air pockets can cause oil starvation at
the bearings.
Note: The heat exchanger installation is a
Sundyne assembly and should not be
rearranged. The heat exchanger is
NEVER mounted higher than the filter.

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Figure 6. Heat Exchanger Mounting for removed when the heat exchanger is not being
MA01AA01 (units prior to 1991) used.

Remote Heat Exchanger

All air-cooled heat exchangers as well as some
large water-cooled heat exchangers must be
mounted away from the gearbox.
Note: Interconnecting piping is the
purchaser’s responsibility unless the
piping is included with packaged units.
All connecting piping, including fittings, must not
exceed 20’ (6m). The minimum requirement of
all piping is 5/8” (16mm) inner diameter (I.D.)
The MA01AA01 model requires a ¼” socket- tubing or piping. If pipe lengths exceed 20’ (6m),
head pipe plug in the filter manifold when using then the pipe diameter must be increased
the gearbox heat exchanger. The plug must be accordingly.

Gearbox Sump
The gearbox sump holds approximately seven Overfilling will cause overheating/
U.S. quarts (6.6 liters) of oil, not including the oil excessive foaming.
contained within the auxiliary piping and heat
exchanger. The oil level must always be Gearbox Sump Heater (optional)
maintained as recommended by Sundyne. When gearbox oil temperature falls below –20°F
(-29°C) it becomes too viscous for proper lube
Note: Sundyne recommends that the oil level pump operation. A sump heater is required
must be within ¼” of top of the round when these conditions may exist. Two types of
sight glass when the machine is static sump heaters are recommended for these
(refer to the mark labeled “MAX”).When conditions–electric or steam.
the pump is in operation, the level will
be approximately ¼” below the MAX
level, with bubbles filling the rest of the
glass. Do not overfill the gearbox.

SundGard Oil Filter

The specially designed oil filter is rated for 3 The gearbox oil and filter should be changed
microns at a beta ratio of 200. every six months. Refer to the Lube Oil
Specifications in the Specification section of this
Note: Oil filters other than Sundgard-OEM manual for more information.
filters will void the Sundyne warranty.

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Main Lube Pump and Lube Oil Priming Kit

Note: Use the auxiliary lube oil priming pump To start the pump, allow the pre-lube pump to
to circulate oil around the heater when run for approximately 30 seconds. There should
the main drive motor is not running. be a minimum indication of 7 psig (0.5kg/cm2)
maintained for 30 seconds before starting the
The main lube pump is a positive displacement main driver. If the oil piping has been drained,
gear type pump directly driven by the input shaft. allow several minutes of operation to bleed
A pre-lube system is required on some pumps. trapped air from the system.
The kit consists of: Note: Only allow shut down of pre-lube pump
• Motor driven positive displacement after main driver is at full operating
pump speed.

• Check valve
• Gages
• Necessary piping Figure 7. Lube Oil Schematic

Oil Pressure
During normal operation the gearbox internal configuration and characteristics of the oil being
lube pump will maintain oil pressure between 15 used.
and 60 psig (1.0 and 4.2kg/cm2). This oil
pressure can vary depending on the bearing Note: Never operate the gearbox with oil
pressure less than 10 psig (0.7 kg/cm2)

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START UP
Start-Up Procedures
Perform the following tasks to start the Sundyne the oil filter (item 924g) manifold and fill the
pump. oil filter and the heat exchanger with oil
(Figure 6).
1. Run-in of pump: If the pump is to be run
under conditions which are considerably 7. Prime the lube oil system
different from those conditions listed on the
The following actions must occur at the time
spec sheet (such as a change in specific
of initial pump installation and following
gravity, suction pressure, flow rate, etc.) the
every re-installation after maintenance that
factory should be consulted to ensure that
required the draining/removal of the gearbox
the run-in conditions are compatible with the
lubricating fluid.
pump.
Verify that gearbox lube oil pressure will be
2. Check to ensure that the driver has been
achieved by priming the lube oil system and
serviced per instructions provided by the
expelling all of the air that is potentially
driver manufacturer.
trapped. Priming can be achieved by either
3. Auxiliaries - Check utility connections; verify operating the (optional) auxiliary lube oil
that auxiliary piping is per Sundyne priming pump or by jogging the main driver
drawings; verify switch and instrument connected to the gearbox (oil pressure
connections and set points; calibrate flow should be observed by the second or third
instruments and other transmitters. jog - each of 2-3 seconds duration).
4. Flushing screens should be installed in all Note: Jogging is required for initial
field assembled piping connections. installation or following re-
5. Check the pump specification sheet and installation after maintenance and
outline drawings for seal environment re-filling of gearbox lubricant. Units
requirements. Be sure seal housing port remaining idle should be jogged
piping is properly connected. If double seals once a month to prevent the
are used, buffer fluid must be pressurized bearings from brinelling and to
before suction pressure is applied to the prevent internal rusting.
pump. Port 1 must be open. Maximum Jogging is also used to verify proper
allowable back pressure on Port 1 is 5 psig direction of rotation for the main driver.
(0.35 kg/cm2). Jogging is a prudent, conservative activity
6. Fill the gearbox with oil. that can be quite useful to ensure long
service life of the Sundyne high-speed
Remove the gearbox fill-vent plug and the products by providing a fluid film of lubricant
filter-breather cap from the fill opening on on the surfaces of bearings and gears.
the gearbox. Fill gearbox within ¼ inch (6.4
mm) from top of oil level sight glass with After priming the lube oil system, check the
lube oil which conforms to the specification oil level in the gearbox sump, and add oil as
in Table 9. Where applicable, operate necessary.
auxiliary lube pump to fill heat exchanger Note: Never start the pump against a
and filter. Add oil as necessary through fill closed discharge valve. Always
fitting until oil level stabilizes in sight glass. check to ensure that the discharge
The gearbox alone requires approximately 7 valve is partially open.
quarts (6.6 liters). Replace the filter
breather cap on the fill-opening fitting and After priming the lube oil system as defined
replace the fill-vent plug. If an auxiliary lube above, the pump can now be routinely
pump is not used, remove the plug on top of started without the need of jogging. This

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would include switching of main/stand-by switches and time delays can be used if
units, start-up of idle reserve units, start-up automatic start sequences are desired.
of emergency units, etc. Non-operating
c) After the start of the main driver, oil
units should be started/used every 9-12
pressure will be supplied by the main
months on an alternating basis.
lube pump inside the gearbox. An
8. If an auxiliary lube system is installed, it increase in oil pressure should be
should be used in the following manner. observed. Shut down the auxiliary pump
within two minutes of the main driver
a) At the initial startup or after changing the
start.
lube oil, run the pump for several
minutes to work any trapped air out of 9. Adjust the heat exchanger cooling flow to
the piping. Adjust the relief valve on the regulate the gearbox sump temperature
auxiliary pump to provide 25 psi (1.76 between 140° and 160°F (60o and 71°C).
kg/cm2) oil pressure to the system. Approximately one hour may be required to
stabilize the temperature.
b) The auxiliary system is intended to
provide oil before starting the main
Maximum recommended temperature is
driver. It should run for a minimum of 5
180°F (82°C).
seconds at minimum pressure before
the main driver is started. Pressure

Controlling the Pump During Startup

To ensure control of the pump during start up, 1. Start the first unit as described in the
follow the start up procedures for your desired Single Operation instructions.
configuration.
2. Start the second unit with the bypass
valve set to maintain the flow above
Single Operation minimum flow.
Start the pump with the suction valve open while 3. Open the discharge valve on the second
throttling the discharge valve. This will ensure unit so that the design flow of both units
that the pump will reach the design flow is maintained.
operating point.
Note: Do not operate the pumps at their peak
If the process fluid is near its vapor pressure,
head capability.
open the supply vessel seal cavity vent so that
the pump can fill with liquid. Sundyne recommends that separate flow
controls be used on each pump to provide a
Parallel Operation lower minimum flow range than is achieved by
pressure control.
To prevent back-flow, place check valves in the
discharge piping of each pump.
Note: Sundyne recommends installing
separate bypass loops around each
pump for additional operational
flexibility.

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OPERATION & CONTROL

Operation of Sundyne Pumps
Under normal operation, several factors must be primarily when a control valve is located an
taken into consideration to ensure successful excessive distance downstream from the pump.
pump operation. Experienced pump operators
will be aware of jeopardizing factors and their Entrained Gases
effects.
The head and capacity of centrifugal pumps will
Suction Conditions
be reduced by gas that is drawn in with the
liquid. Under normal operating conditions,
Improper flow of liquid into the impeller is the centrifugal pumps can tolerate up to 2% of gas
most common operational abuse of centrifugal (by volume). Entrained gases can cause
pumps. Two conditions must exist to prevent damage to mechanical seals with the exception
turbulence at the eye of the impeller. of double seals. If you have entrained gas,
contact Sundyne for further instruction.
• Proper suction piping, see suction piping
section.
System Head Curve
• Liquid reaching the impeller eye must
The point of intersection between the system
have enough vapor pressure to prevent
curve and the pump characteristic curve
the fluid from flashing to a gas in the
determines the flow or operation for the
impeller. If this condition occurs, it will
centrifugal pump. For steady flow to occur, the
cause cavitation, which can damage the
system curve must intersect the pump
impeller and inducer. When centrifugal
characteristic curve at a significant angle. The
pumps cavitate the noise sounds like the
following diagram gives examples of satisfactory
pump is “pumping gravel”. In high speed,
and unsatisfactory angles of intersection.
single stage pumps, this sound may not
be discernable. Cavitation can be Figure 8. Typical Operation
prevented by maintaining suction pressure
at a high enough level and suction
temperatures low enough to maintain Net
Positive Suction Head (NPSHa) available
greater than Net Positive Suction Head
(NPSHr) required by the pumps.

Minimum Flow Conditions

Vibration and noise will occur during operation of
centrifugal pumps if either of two conditions
exist:
• Internal flow separations
• Recirculation at low flow conditions
If the operator is noticing excessive noise or
vibration, operation must be suspended until the
cause is determined and corrected. Continued
use may cause damage to the pump.
Resonance in the discharge line can accentuate
noise, vibration, and damage to the pump,
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Note: The curve for pump A has a significant Figure 9. Parallel Operation
angle of intersection with system curves
D and E. The system curve D could
represent a system with the control
valve wide open while curve E could
represent the same system but with the
throttle valve closed to reduce flow from
flow 1 to flow 2. Pump curve B, on the
other hand, will provide only flow 2,
even with the control valve wide open
(curve D). When the control valve is
partially closed to create system curve
E, the curve E and lower pump curve B
are practically parallel. The lack of a
significant angle of intersection means FLOW
that the system is unstable, pump flow
is likely to fluctuate erratically and not Figure 10. Parallel Units Common Valve
respond to control valve position.

Parallel Operation
Maximizing control is critical when operating
centrifugal pumps in parallel. One pump can
overpower the other in regards to head at a
lower total flow. If a simple, unrestricted manifold
connects two pumps at the discharge head, the
discharge head of one pump is imposed on the
other. All pumps will see the same discharge
head at a given time. This is demonstrated on The pressure in the manifold is set at P1; the
the following diagrams. flow through pump A indicated as A1 on the
The characteristic curves of two pumps preceding curve. At the same time, the flow
designated A and B are demonstrated in the through pump B is indicated as B1. However, if
Parallel Operation figure. the throttle valve is closed to cause the manifold
pressure P to rise to P2, then flows through
Since no two pumps will have exactly the same pump A and B are A2 and B2 respectively. If the
performance, it is assumed that pump A throttle valve were closed even further, then
produces a slight amount more head than pump pump B would cease to flow entirely. Since
B. The pumps are arranged with a common pump B would effectively be deadheaded, the
manifold as shown in Parallel Units Common fluid in it would heat up and boil. During internal
Valve figure. boiling, it could encounter liquid slugging and
probable damage to the pump. Proper selection
of a control system can prevent this situation.

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MAINTENANCE
Disassembly of LMV-311

STEP 1 STEP 3
Remove attached hardware and lift the driver up
off the gearbox. Remove the nuts from the pump Install the anti-rotation device to prevent
casing studs. Lift the gearbox and seal housing impeller from spinning.
up off of the pump casing.
Note: Ensure the impeller is protected from
coming in contact with any objects that
may cause damage.

Lifting gearbox from pump casing.

STEP 2
Remove vent cap from gearbox.

Installing anti-rotation device

Note: Plate the gearbox on a suitable support

with the impeller pointing upward.

Note: Tool number TO01AK02 for keyed input

shaft and TO01AK03 for splined input
shaft.

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STEP 4 STEP 6
Remove inducer or impeller nut. Remove diffuser cover using prying tools.
Note: Left hand thread. Note: Groove on side of diffuser cover is for
prying, and not for an o-ring.

Tandem seal arrangement is shown in

the following disassembly steps.

STEP 7
STEP 5
Remove mechanical seal mating ring.
Remove impeller using prying tools.
Note: The impeller is dynamically balanced
and must be replaced or rebalanced if
any signs of damage are visible.

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STEP 9
Remove lower shaft sleeve and o-rings
above and below shaft sleeve.

Mating ring should slide right off.

STEP 8
Remove lower mechanical seal.
Use extraction tool to slide o-rings up the
shaft.

Notice shaft sleeve next to impeller side o-ring.

Remove three hex head screws and washers.

Note: Tandem configuration shown.

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STEP 10 STEP 12
Remove tandem-mating ring. Remove seal housing.
Note: Use “S” hooks or eyebolts and hoist
when possible to avoid personal injury.

Use extraction tools to slide up, over shaft.

STEP 11
Remove four bolts holding seal housing.

Lifting the seal housing using a hoist.

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STEP 13 STEP 15
Turn seal housing over and remove upper Remove upper shaft sleeve.
seal from seal housing.

Remove three hex head screws and washers.

STEP 16
Remove gearbox seal screws and gearbox
seal.

Upper mechanical seal.

STEP 14
Remove the o-ring from the upper shaft
sleeve.
Removing three hex head screws.

Note: The gearbox mechanical seal can be

replaced or rebuilt.

Use extraction tool to remove o-ring.

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STEP 17 STEP 19
Remove gearbox seal o-ring. Invert the gearbox and remove fill and vent
fitting.

Use a pipe wrench to remove the ¾ inch pipe

elbow first. Next, use the pipe wrench to loosen
the pipe and remove from the gearbox.

Use extraction tool to remove o-ring.

STEP 18
Remove gearbox seal mating ring.

Slide the fill and vent pipe out of gearbox.

Remove mating ring with extraction tools.

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STEP 20 STEP 22
Loosen and remove gearbox bolts, (7 total). Drive close tolerance alignment pins out, (2
pins).

STEP 21
Loosen close tolerance alignment pin.
Use hammer to tap pin out.

STEP 23
Remove upper gearbox housing.
A mallet can be used to tap around the edges of
the housing to loosen the idler shaft and assist
the housing in lifting off.
Note: Use hooks or eyebolts and a hoist
when possible to avoid personal injury.

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STEP 24 STEP 26
Remove the lube pump spring and the lube
Remove idler shaft assembly.
pump.
Removing the idler shaft assembly disengages
the upper idler and input shaft gears.

STEP 27
Technician is pointing to idler shaft.

STEP 25 Inspect the condition of the lube pump anti-

rotation pin.
Remove input shaft assembly.

Extraction tool is touching anti-rotation pin.

STEP 28
Remove bearing plate.

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STEP 29 STEP 32
Remove and inspect upper thrust washer. Remove the lower thrust washer.

Washer will slide off of the shaft.

STEP 30
Remove idler shaft assembly.

STEP 33
Remove and inspect upper journal bearing
after removing from bearing plate.

STEP 31
Remove high-speed shaft assembly.

Unscrew three hex head screws.

Use fingers to remove journal bearing.

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STEP 36
Remove lower journal bearing.

Inspect the upper journal bearing for damage or

signs of excessive wear. Repeat step 33 for removal of lower journal
bearing.
STEP 34
STEP 37
Remove input shaft seal.
Remove lower bearing shims.

STEP 38
Remove all the lube jets in lower and upper
housing.
STEP 35
Remove the sump tube.

Use hex key to remove the lube jets.

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STEP 39 STEP 41
Blow out lube passage. Lift the diffuser from the pump case.
Note: Use hoist when available to prevent
personal injury.

Using air tool to blow out lube passages.

Blowing out lube passages.

STEP 40
Remove diffuser from the pump case.

Install three 5/16 eyebolts into the diffuser to use

for hoisting the diffuser off of the pump case.

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Inspection, Cleaning and Repair

Inspecting All Bearings if they show signs of metal pick-up or

overheating, install a new bearing assembly.
Not\e: The radial “free play” of the high speed
shaft can be as high as 0.011 inch
(0.28mm) due to the clearance in the
bearings. It is not possible to check for
shaft straightness while the gearbox is
assembled. To check straightness, the
shaft must be placed in V-blocks, on it’s
bearing journals, and have runout
measured at the impeller fit (0.0018
inch TIR max).

Replace bearings if: Gearbox Mechanical Seal

Carefully inspect the seals for abrasive particles,
• They have been in operation for over excessive seal face wear and any binding of the
three years seal face washer.
• If rotation is not smooth Replace or rebuild a faulty mechanical seal.
• If outside of inside diameters are worn Seals may be rebuilt by replacing the seal face
washer, wedge rings, o-ring, and springs. A seal
Note: Only replace bearings with repair kit is available.
manufacturer’s approved replacement
bearings. Non-approved bearings may Replace or lap the seal rotating face if the wear
jeopardize the mechanical integrity of track is rough or worn to a depth greater than 2
the gearbox and pump. helium light bands.
A combined total of 0.010 inch (0.25mm)
Note: Refer to the Specifications section of maximum may be removed from the surfaces of
the manual for all bearing and shaft the pump and gearbox seal rotating faces.
clearances. Excess material removal will result in incorrect
seal face loading causing increased seal
High-Speed Shaft leakage.

Inspect the High Speed Shaft at the thrust Remove any high spots on the end surfaces of
washer and journal bearing contact areas. the lower shaft sleeve and impeller hub to insure
Replace the shaft and gear assembly if: that the seal rotating face will not be distorted by
clamping force of the impeller bolt.
• Outside diameter of shaft is less than
1.4960 inches Reassemble the seal, throttle bushing, if used
seal housing, and impeller using an o-ring repair
• If the shaft has bearing or washer kit. All o-rings that were disturbed by
materials on it’s surface disassembly should be replaced. During
reassembly, carefully check the torque values
• Shows signs of overheating listed in Table 12.
• Shows wear to a depth greater than The impeller may rub on the diffuser cover plate
0.001” (0.03mm) (15) until o-rings (936D and 936E) are
Inspect upper and lower thrust washers or tilting compressed by tightening hex nuts (914A).
pad bearing assembly. If metal is smeared into Check the gearbox input shaft for freedom of
radial lube grooves of the washer face, install a rotation after the pump is assembled and all
new washer. If the tilting pads do not fit freely, or bolts are tightened per Table 12.

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Shaft Sleeve
Ensure that there are no high spots on the end
surfaces of the shaft sleeve or the impeller hub.
High spots will distort the seal rotating face due
to the clamping force of the impeller bolt. Ensure
that shaft sleeve end faces are parallel within
0.0003” (0.0076mm).

Bearing and Shaft Clearances

Figure 11. Bearing and Shaft Clearances

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Reassembly of the LMV-311

STEP 1 STEP 2 continued

Insert shim under lower journal bearing.

STEP 2
Install lower journal bearing.
Note: Using a torque wrench to tighten
screws.

STEP 3
Install lower thrust washer if not already in
place.

Insert 3 hex head screws.

Note:: Torque to 40 in-lbs

Note: Torque screws to:

STEP 4
Sundyne Item English Metric
Standard 905M 40 in-lbs 4.5 N-m

Install high-speed shaft assembly.

Note: Above picture has thrust washer
already installed over journal bearing.

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STEP 5 Note:: A light coating of lubricant may be

used to hold item 155B in place.
Re-install the sump tube into the bearing
STEP 8
plate.

Install bearing plate without gasket using

alignment pins.

STEP 6
Re-install the upper journal bearing into the
bearing plate.
Using alignment pin to install the bearing plate
temporarily.

STEP 9
Clamp bearing plate to the lower gearbox
housing.

Note: Torque screws to:

Sundyne Item English Metric

Standard 905M 40 in-lbs 4.5 N-m

STEP 7 Clamping the bearing plate to housing.

Install new thrust washer. Note:: “C” clamps can be utilized to perform
this task.

Thrust washer is silver disc in center.

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STEP 10
STEP 12
Inspect endplay of the high-speed shaft.
Lubricate the lower idler bearing.
Note:: Endplay must fall within these
tolerances, 0.015” +/- 0.002”

STEP 13
Install idler shaft assembly.

Measuring endplay of High Speed Shaft.

Note: For complete instructions for checking
endplay refer to the “Procedure for
Checking High Speed Shaft Endplay”
later in this manual.

STEP 11
Remove bearing plate and install lower
housing o-ring (936AG) and o-ring at oil Note: The idler shaft assembly sits at a slight
passage (936N). tilt to allow installation of the bearing
plate.
936AG

936N
Lubricate the journal bearings, high-speed
shaft, journal / thrust face with standard
gearbox lubricant.

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STEP 14 STEP 17
Install the bearing plate. Lubricate the lube pump.

STEP 15
Install lube pump.
STEP 18
Install input shaft assembly.

STEP 16
Install lube pump spring.
Note: Notice the input slots for the oil pump
drive pins.

STEP 19
Push on input shaft to verify engagement of
drive pins.

The lube spring sits inside the lube pump.

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STEP 20 STEP 22
Set idler shaft assembly in place and engage
Install upper gearbox housing.
input gears.
Note: Lower carefully in order to slide
bearings into bearing liners.

STEP 21
Lube input shaft bearings and upper idler Note: Use hoist when available to prevent
bearings. personal injury.
Install upper housing o-ring (936AG) and
o-ring at oil passage (936T). STEP 23
Install close tolerance alignment pins.

936AG 936T

Note:: Install first pin as noted on the bearing

plate.

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STEP 24
STEP 24 continued
Install new lip seal.
Note: Use lip seal installation tool
#T-H006AA-47 to install lip seal.

Putting lip seal onto lip seal installation tool.

Installing the lip seal.

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STEP 24 (Alternate)
Apply Lubricant.
STEP 25
Install remainder of gearbox hex head bolts.

STEP 24 (Alternate part 2) continued

Install the cartridge seal.

Installing washers and nuts onto gearbox bolts.

Note: Torque screws to:
Sundyne Item English Metric
Standard 909B 65 ft-lbs 88 N-m

STEP 26
Install fill and vent fitting.
Note: Use pipe dope on all pipe threads. Use
pipe wrench to tighten fitting after
sliding into place.

STEP 24 (Alternate part 3) continued

Install input seal. Use a pipe to tap cartridge
seal into place

Note: Do not use Teflon tape on connections

to gearbox as this may result in
lubrication system malfunction.

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STEP 27
Install shaft anti-rotation device to prevent
the impeller from spinning.
Note: Tool number TO01AK02 for keyed input
shaft and TO01AK03 for splined input
shaft..

STEP 28
Turn gearbox over.

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Gearbox Seal Assembly

STEP 1 STEP 3
Install gearbox-mating ring.
Install gearbox seal. Install three gearbox
seal hex head screws.

Note: Chamfer on mating ring should be

toward gearbox. Note: Torque screws to:
Sundyne Item English Metric
STEP 2 Standard 905L 75-80 in-lb 8.5-9.0 N-m

Install gearbox seal o-ring (936P) onto

gearbox seal.

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Steps for Single Seal Only

STEP 1
Install thermal barrier gasket.
STEP 4
Install o-ring (936H) on throttle bushing.

STEP 2
Install o-ring (936K) followed by shaft sleeve.

STEP 5
Install throttle bushing on the seal housing
and torque throttle bushing screws.

STEP 3
Install o-ring (936J).

Note: Torque screws to:

Sundyne Item English Metric
Standard 905F 95-102 in-lbs 11-11.5 N-m
Nace Item English Metric
Compliant 905F 70-75 in-lbs 8-8.5 N-m

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STEP 6 STEP 9
Install seal on housing on gearbox. Install mechanical seal and torque.

Note: Torque screws to:

Note: Use "S" hooks or eyebolts and hoist when
Sundyne Item English Metric
available to prevent personal injury. Standard 905E 95-102 in-lbs 11-11.5 N-m
STEP 7 Nace Item English Metric
Compliant 905E 70-75 in-lbs 8-8.5 N-m
Install and torque seal housing cap screws.

**Skip to page 56 for Instructions on

the Throat Bushing Option.**

STEP 10
Install seal mating ring.

Note: Torque screws to:

Sundyne Item English Metric
Standard 905A 35-40 ft-lbs 47-54 N-m
Nace Item English Metric
Compliant 905A 27-30 ft-lbs 37-40 N-m

STEP 8
Install o-ring (936H) on mechanical seal.
**Continue on page 58**

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Steps for Dual Pressurized

(Double Seal) Only

STEP 1 STEP 3
Install the thermal barrier gasket. Install o-ring (936J).

STEP 4
Install o-ring (936H).

STEP 2
Install o-ring (936K) followed by the shaft
sleeve.

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STEP 5
STEP 7
Install upper seal and torque.
Install seal housing cap screws and torque.

Note: Torque screws to:

Sundyne Item English Metric
Standard 905F 95-102 in-lbs 11-11.5 N-m
Note: Torque screws to:
Nace Item English Metric
Compliant 905F 95-102 in-lbs 11-11.5 N-m Sundyne Item English Metric
Standard 905A 35-40 ft-lbs 47-54 N-m

STEP 6 Nace
Compliant
Item
905A
English
27-30 ft-lbs
Metric
37-40 N-m
Use a hoist to lift seal housing.
STEP 8
Install mating ring.

CAUTION! Dropping or rough handling of

mating rings may result in micro
cracks resulting in seal failure.

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STEP 9 STEP 12
Install lower seal and torque.
Install o-ring (936J).

STEP 10 Note: Torque screws to:

Sundyne Item English Metric
Install the seal spacer, chamfer toward seal. Standard 905G 95-102 in-lbs 11-11.5 N-m
Nace Item English Metric
Compliant 905G 70-75 in-lbs 8-8.5 N-m

STEP 13
Install shaft sleeve.

STEP 11
Install o-ring (936H).

**Continue on page 58**

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Steps for Dual Unpressurized

(Tandem) Seal Only

STEP 4
STEP 1
Install o-ring (936H).
Install the thermal barrier gasket.

STEP 5
Install upper seal and torque.
STEP 2
Install o-ring (936K) followed by the shaft
sleeve.

Note: Torque screws to:

STEP 3 Sundyne Item English Metric
Standard 905F 95-102 in-lbs 11-11.5 N-m
Install o-ring (936J).
Nace Item English Metric
Compliant 905F 70-75 in-lbs 8-8.5 N-m

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STEP 6 STEP 9
Use a hoist to lift seal housing. Install o-ring (936J).

STEP 10
Install o-ring (936H).

STEP 7
Install seal housing cap screws and torque.

STEP 11
Install seal and torque.

Note: Torque screws to:

Sundyne Item English Metric
Standard 905A 35-40 ft-lbs 47-54 N-m
Nace Item English Metric
Compliant 905A 27-30 ft-lbs 37-40 N-m

STEP 8
Install mating ring.

Note: Torque screws to:

Sundyne Item English Metric
Standard 905E 95-102 in-lbs 11-11.5 N-m
Nace Item English Metric
Compliant 905E 70-75 in-lbs 8-8.5 N-m

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STEP 12 STEP 14
Install shaft sleeve.
Install mating ring.

STEP 13
Install o-ring (936J).
**Continue on page 58**

**Skip to page 56 for Instructions on

the Throat Bushing Option.**

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Steps for Single Seal with Isolation Bushing Only

STEP 1 STEP 4
Install the thermal barrier gasket.
Install o-ring (936H).

STEP 5
STEP 2 Install the upper seal and torque.
Install o-ring (936K) followed by the shaft
sleeve.

STEP 3 Note: Torque screws to:

Sundyne Item English Metric
Install o-ring (936J). Standard 905E 95-102 in-lbs 11-11.5 N-m
Nace Item English Metric
Compliant 905E 70-75 in-lbs 8-8.5 N-m

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STEP 6 STEP 8
Use a hoist to lift the seal housing. Install the mating ring.

STEP 9
Install o-ring (936J).

STEP 7
Install the seal housing cap screws and
torque.

STEP 10
Install o-ring (936H).

Note: Torque screws to:

Sundyne Item English Metric
Standard 905A 35-40 ft-lbs 47-54 N-m
Nace Item English Metric
Compliant 905A 27-30 f5-lbs 37-40 N-m

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STEP 11
Install the isolation bushing and torque.

Note: Torque screws to:

Sundyne Item English Metric
Standard 905G 95-102 in-lbs. 11-1.5 N-m
Nace Item English Metric
Compliant 905G 70-75 in-lbs 8-8.5 N-m

STEP 12
Install the shaft sleeve.

**Continue on page 58**

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Steps for Single Seal with Steam Bushing Only

STEP 1 STEP 3
Install o-ring (936K) followed by the shaft Install o-ring (936H) on steam bushing.
sleeve.

STEP 2 STEP 4
Install o-ring (936J). Install steam bushing on the seal housing
and torque steam bushing screws.

Note: Torque screws to:

Sundyne Item English Metric
Standard 905F 95-102 in-lbs 11-11.5 N-m
Nace Item English Metric
Compliant 905F 70-75 in-lbs 8-8.5 N-m

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STEP 5 STEP 7
Use hoist to lift seal housing on gearbox. Install o-ring (936H) on mechanical seal.

STEP 8
Note: Use "S" hooks or eyebolts and hoist when Install mechanical seal and torque.
available to prevent personal injury.

STEP 6
Install and torque seal housing cap screws.

Note: Torque screws to:

Note: Torque screws to: Sundyne Item English Metric

Standard 905E 95-102 In-lbs 11-11.5 N-m
Sundyne Item English Metric
Standard 905A 35-40 ft-lbs 47-54 N-m Nace Item English Metric
Compliant 905E 70-75 in-lbs 8-8.5 N-m
Nace Item English Metric
Compliant 905A 27-30 ft-lbs 37-40 N-m

**Skip to page 56 for Instructions on

the Throat Bushing Option.**

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STEP 9
Install seal mating ring.

**Continue on page 58**

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Throat Bushing Option for Single Seal and Tandem Seal Only

STEP 1 STEP 4
Install o-ring (936G) on the mating ring.
Make sure the notch on the throat bushing
lines up with the pin on the diffuser cover
plate.

STEP 2
Install seal mating ring.

STEP 5
Install retaining ring.

STEP 3
Install o-ring (936S) on throat bushing and
place into the diffuser cover plate.

936S o-ring

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STEP 6 STEP 8
Install o-ring (936E) on the diffuser plate. Install the diffuser plate.

STEP 7
Install o-ring (936D) on the diffuser plate.

STEP 9
Install shaft sleeve SL01AA19.

**Skip to Impeller Installation

Step 4 on page 58**

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Continuation for Single, Dual Pressurized (Double), Tandem,

and Steam Bushing Assemblies
(If Throat Bushing Does Not Apply)

STEP 1 STEP 3
Install o-ring (936E) on diffuser plate. Install the diffuser cover onto the gearbox.

STEP 2
Install o-ring (936D) on diffuser plate.
Note: Rotate cover to engage alignment pin
with hole in seal housing.

STEP 4
Install impeller o-ring (936G).

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STEP 5 STEP 8
Install impeller.
Install impeller bolt.

Note: Fully engage impeller bolt into the

STEP 6 impeller nut or inducer before installing
into the assembly
Install tab washer.

STEP 9
Torque impeller bolt or inducer.

STEP 7
Install o-ring (936F).

Note: Torque impeller bolt / inducer to:

Sundyne Item English Metric
Standard 3 36-40 ft-lbs 49-54 N-m
Nace Item English Metric
Compliant 3 36-40 ft-lbs 49-54 N-m

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STEP 10 STEP 13
Replace upper diffuser o-ring (936B). Lower the diffuser back onto the pump case.

STEP 11
Install lower diffuser o-ring (936C).
Note: Lower diffuser o-ring may require
stretching before installation.

STEP 14
Install seal housing and gearbox onto the
pump case.

Step 12

Lower diffuser o-ring inside the pump case.

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STEP 15
Note: The impeller may rub on the diffuser
cover plate until all the o-rings are
Install pump case nuts onto casing studs. compressed by the tightening of the
hex nuts.
Note: Tighten casing nuts according to the
Torque Specification Table.
Note: When installing new anti-friction
bearings, bearings should be pressed
onto the shaft using a press which only
contacts the inner race. Bearing
damage will occur by pressing or
pulling the outer race. No more than
0.001 inch (0.03mm) gap should exist
between the bearings, spacers, gears,
and shaft shoulders.

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Procedure for Checking the High-Speed Shaft Endplay

The endplay of the shaft MUST be measured if within this limit, calculate the shim thickness
any of the following parts have been replaced: required to place the shaft within the proper
clearance range. Select the required thickness
• High speed shaft assembly shim using 158 series shim spacer sizes.
• Thrust washer
• Output housing STEP 6
Remove the alignment bolts (909C) and bearing
• Journal bearing plate (102) with upper journal bearing (151B).
• Bearing plate
Sundyne recommends checking endplay during STEP 7
any re-assembly. Remove the high-speed shaft, thrust washers (if
used), and the lower journal bearing.
To obtain correct shaft endplay shim spacers
must be installed as required.
STEP 8
Note: All parts must be dry and free of oil.
Install the required shim spacers in place on the
gearbox output housing and replace the lower
STEP 1 journal bearing. Install attaching bolts (905M)
Install the lower journal bearing (151A) into the and tighten.
gearbox output housing (101A). With no shim
spacers installed, tighten screws (905M). STEP 9
Repeat steps 3-5 to verify correct endplay. If
STEP 2 within specifications, proceed to step 10. If
Install the upper journal bearing or bearing outside of tolerances, recalculate shims required
assembly (151B) into the bearing plate (102). and repeat steps 3-9.
With no shim spacers installed, tighten screws
(905N). STEP 10
Install the lower thrust washer (155A-if used)
STEP 3 with the flat side on the bearing surface and
If used, place both upper and lower thrust replace the high-speed shaft.
washers (155B and 155A) into the upper and
lower journal bearings. Place the high-speed STEP 11
shaft assembly into the gearbox output housing. Install the upper thrust washer (155B-if used)
with the flat side on the journal bearing’s
STEP 4 surface. A light grease may be used to hold the
Install the bearing plate (102) using two large- thrust washer in place.
diameter alignment bolts (909C). Do not install Note: Never install shims behind the upper
the o-ring and gasket. Clamp the bearing plate journal bearing.
to the output housing with two “C” clamps or
bolts.
STEP 12
STEP 5 Continue the reassembly of the gearbox by
placing the idler shaft (140) in the lower half of
With the shaft in a vertical position, move the
the gearbox. Do not allow the idler shafts lower
shaft up and down while measuring the total
ball bearing to slide into the bearing retainer at
endplay with a dial indicator or depth
this stage of the assembly.
micrometer. Shaft endplay must be 0.015 ±
0.002-inch (0.38 ± 0.05 mm). If endplay is not
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STEP 13
Position the bearing plate (102) on the lower half
of the gearbox. Ensure that the lube passage
o-rings (936T) and housing gaskets (105) are
positioned correctly.

STEP 14
Install the low speed shaft assembly into the
bearing plate bearing liner with the shaft aligned
so that the lube pump drive pins slip into the low
speed shaft. The top surface of the bearing
should be even with the top of the bearing liner.
The idler shaft can then be allowed to drop into
the lower bearing liner, engaging the four gears.

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TROUBLESHOOTING
Gearbox & Pump Diagnostics
Several system factors may affect the • Flow rate
performance of the pump. These factors are:
• Control characteristics
• Temperature
These factors as well as internal problems must
• Specific gravity be considered when analyzing pump system
performance. The following table gives
• Suction pressure diagnostic information that can be useful when
• Driver speed analyzing gearbox and pump performance
problems.
Table 1. Gearbox and Pump Diagnostics

Situation/Symptom Possible Cause Investigative/Corrective Action

No flow, no pressure at Pump not completely filled with liquid. Bleed all vapor or air from port 6.
start-up.
Allow more cool-down time if pumping low
temperature fluid.
Check suction line for air leak if suction
pressure is lower than atmospheric.

NPSH actually lower than NPSH requirement listed on Suction line blocked – check suction screen
specification sheet. and valve.
Excessive pressure drop through suction
piping.
Flow restricted by vapor pockets in high points
of suction line.
Suction tank level or pressure too low.
Entrained air or vapor in pumped fluid.
NPSH reduced by presence of more volatile
fluid in process fluid.

Failure of drive component, such as interconnecting Disassemble and inspect.

shaft or impeller key, or item missing from assembly.

Reverse direction of rotation. Direction of driver shaft rotation must be as

shown by arrow on pump casing. Note: Impeller
and driver rotate in the same direction.

Insufficient total head. Flow too high. Check total head and flow rate against
performance curve.

Wrong direction of driver shaft rotation. (It is possible Direction of driver shaft rotation must be as
for the pump to develop greater than 50 percent shown by arrow on pump casing. Note: Impeller
design total head in this condition). and driver rotate in the same direction.

NPSH actually lower than NPSH requirement listed on Refer to solutions listed under “No flow, no
specification sheet. pressure at start-up”.

Flow too low, causing overheating of fluid resulting in Increase through-flow rate.
internal boiling and unstable pump operation.
Bypass part of pump discharge to supply tank.

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Situation/Symptom Possible Cause Investigative/Corrective Action

Diffuser discharge throat partially plugged or Clean these areas of all obstructions and restore
impeller damaged by passage of a solid particle. surfaces to a smooth polished finish free of all
corrosion pitting. Edge of diffuser throat must be
sharp.

Corrosion and/or erosion of diffuser throat (may If edge of throat is no longer sharp and smooth
also be accompanied by corrosion/ erosion of or has opened in size, head-rise may be
diffuser and cover surface adjacent to impeller). reduced. Opening of the inlet area of the throat
Insufficient total head will result in higher flow rate and horsepower
cont. consumption. Corrosion/erosion of diffuser and
cover surfaces will result in a significant
horsepower increase.

Excessive recirculation from discharge to inlet. Check flow through external plumbing.
Pump o-ring (936C) damaged or missing.
Integral centrifugal separator orifice worn.

Process fluid specific gravity or viscosity different Check actual viscosity and specific gravity at
from values shown on specification sheet. operating temperature. Viscosity higher than five
centipoise will cause reduced head and flow and
increased power consumption.

Driver speed too low. Check speed against value listed on

specification sheet.

Pressure gauges or flow meters in error Calibrate instrumentation.

Driver overloaded. Fluid specific gravity or viscosity higher than values Check actual viscosity and specific gravity
listed on specification sheet. against value listed on specification sheet.

Electrical failure in electric driver. Check circuit breaker heater size and setting.
Check voltage and voltage balance between
phases.
Current for each phase should be balanced
within three percent.

Mechanical failure in driver, gearbox or pump. Remove driver and check for freedom of rotation,
correct spacing
of pump and gearbox shaft assemblies.
Remove fluid end and search for any mechanical
failure.
Remove gearbox oil level sight glass and inspect
bottom of sump for wear particles. Bearings are
probably not damaged if no wear particles are
present.

Corrosion pitting on surface of diffuser cover or Disassemble pump and inspect. Rough or
diffuser, adjacent to impeller blades. Head rise is pitted surfaces can cause friction losses which
also reduced by this condition. will significantly increase horsepower
consumption. Clean these areas of all
obstruction and restore surfaces to a smooth
polished finish. Check diffuser throat area at
the inlet; erosion or corrosion resulting in
roughness or increased area will increase
horsepower consumption. Note: A larger throat
size than design will allow a higher flow and
horsepower for a given head rise.

Excessive discharge Flow rate too low. Increase flow rate through pump. Add bypass to
pressure pulsations. suction tank if necessary.

Insufficient NPSH available. Refer to solution for insufficient NPSH under “No
flow, no pressure at startup,” above.

Defective flow control valve. Check control valve.

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Situation/Symptom Possible Cause Investigative/Corrective Action

Change of gearbox oil Gearbox oil contaminated with water or process Inspect gearbox heat exchanger for leakage.
from normal color to fluid.
Check for excessive pump seal leakage.
milky pink or yellow
Inspect shaft sleeve o-rings.
Inspect that seal housing port 1 and other seal
drains are open for unrestricted seal leakage
flow.

Shaft sleeve rubs on Gearbox journal bearing failure. Install replacement exchange gearbox or
inside diameter of seal. repair gearbox as outlined under
“Maintenance”.

Excessive gearbox oil Low speed shaft seal (115) leakage. Check upper gearbox housing lip seal drain
consumption. port for leakage. Replace shaft seal if required.

High speed shaft mechanical seal (60C) leakage. Check drain port 1 for leakage. Replace shaft
seal if required.

Leakage through heat exchanger into cooling fluid. Pressure test heat exchanger and replace if
required.

Excessive oil foaming. High oil level. Shut down the unit and check oil level.

Low gearbox temperature. Incorrect lubricant. Adjust coolant to heat exchanger, keeping oil
temperature above 140°F, 60°C.

High gearbox Heat exchanger fouled or coolant shut off. Check coolant flow and/or clean heat
temperature. exchanger.
Oil level too high.
Check oil level and adjust.

Pump Mechanical Seal Diagnostics

The following table contains diagnostic Repair procedures for mechanical seals are
information that is applicable to single seal, listed in this manual under Maintenance.
double seal, and tandem seal equipped units.

Table 2. Pump Mechanical Seal Diagnostics

Situation/Symptom Possible Cause Investigative/Corrective Action

Sudden increase in seal Severe cavitation or loss of suction causing Correct pump suction condition causing
leakage. vibration and bouncing of seal face. cavitation. Bleed vapor from seal cavity and
restart.
Install double seal if loss of suction cannot be
prevented.

Seal icing on low temperature pumps or icing Quench with compatible fluid which will not
when handling fluids which vaporize at a freeze at pump temperature through seal drain
temperature of less than +32°F (0°C) at port 2 or 7 to prevent ice formation on
atmospheric pressure atmospheric side of seal during start-up and in
running condition.
Use purge of dry nitrogen gas through ports
2 or 7.
Install double or tandem seal if ice is caused by
water in process fluid or supply external seal
flush of compatible fluid which does not contain
water.

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Situation/Symptom Possible Cause Investigative/Corrective Action

Sudden increase in Solid particles in seal cavity or seal spring area Inspect for clogged integral centrifugal separator
seal leakage (seal faces usually have rough scratched orifices. Clean orifices if necessary (plan 31 if so
(continued) appearance). equipped.)
Supply external clean seal flush or double seal if
particles cannot be removed by separator.

Seal stationary face spring action is rough and If parts are corroded, replace with parts made
sticky. from compatible materials.
If formation of solids causes sticky seal analyze
fluid properties. Use external seal flush or double
seal arrangement.

Worn or damaged seal. Disassemble seal and rebuild or replace per

instructions in maintenance section.
Wear pattern on seal rotating faces not uniform. Lightly lap surfaces of shaft sleeve and impeller
hub which contact rotating seal face to remove
high spots. Install new seal faces.
Wear pattern on stationary face smooth but not Lap flat or replace seal.
uniform.
Edges of stationary face chipped and seal face Install seal cavity bypass to suction tank.
worn. (Vapor flashing in seal cavity will cause Prevent loss of pump suction.
excessive wear and/or cracking of rotating face.)
Supply cool seal flush.
Install double seal.

Seal rotating face cracked or broken. May be Prevent loss of pump suction or supply
caused by damage at assembly or thermal shock continuous external seal flush.
caused by seal running dry.
Install double seal.

Chemical attack of seal faces, seal parts or Investigate fluid properties and determine
o-rings. suitable materials for replacement.

Excessive radial high speed shaft movement. Check high speed shaft journal bearings and
replace if necessary.
Bent high speed shaft or severe out-of-balance. Check if damage exists on impeller and/or
inducer which will indicate that a large particle
went through the pump.
Deposits on the impeller/inducer causing
unbalance.

Damage to mechanical seal secondary seal Check for erosion and/or corrosion attack.
(Teflon® wedge or U-cup or elastomer o-ring). Install seal flush or double seal arrangement.

Loose stack-up of high-speed shaft attaching Check for correct impeller bolt/inducer torque.
components. Check for cold flow of Teflon® o-rings.

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SPECIFICATIONS
Falk Steelflex Type Coupling Specifications
Table 3. Falk Steelflex Type Coupling Specifications

Falk Coupling End Gap Cover Bolt

Size Minimum Normal Maximum Torque

40T10 0.062 in. 0.125 in. 0.188 in. 100 in-lb

(1.57 mm) (3.17 mm) (4.77 mm) (1.15 kg-m)

50T10 0.062 in. 0.125 in. 0.188 in. 200 in-lb

(1.57 mm) (3.17 mm) (4.77 mm) (2.30 kg-m)

60T10 0.062in. 0.125 in. 0.188 in. 200 in-lb

(1.57 mm) (3.17 mm) (4.77 mm) (2.30 kg-m)

70T10 0.062 in. 0.125 in. 0.188 in. 200 in-lb

(1.57 mm) (3.17 mm) (4.77 mm) (2.30 kg-m)

80T10 0.062 in. 0.125 in. 0.250 in. 200 in-lb

(1.57 mm) (3.17 mm) (6.35 mm) (2.30 kg-m)

Falk Double Gear Type Coupling Specifications

Table 4. Falk Steelflex Type Coupling Specifications

Falk End Gap Operating Limits Bolt

Torque
Coupling Total Indicator

Size Reading

Minimum Normal Maximum Offset Angular

(Maximum) (Maximum)

15G 0.140 in. 0.156 in. 0.172 in. 0.005 in. 0.005 in. 280 in-lb

(3.56 mm) (3.96 mm) (4.36 mm) (0.127 mm) (0.127 mm) (3.22 kg-m)

20G 0.140 in 0.156 in. 0.172 in. 0.005 in. 0.005 in. 420 in-lb

(3.56 mm) (3.96 mm) (4.36 mm) (0.127 mm) (0.127 mm) (4.83 kg-m)

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Falk Double Gear Type-Vertical Specifications

Table 5. Falk Double Gear Type-Vertical Specifications

Operating Limits

Falk Coupling (Total Indicator Limit) Bolt

Size Torque
Offset Angular

(Maximum) (Maximum)
15GL 0.005 in. 0.005 in. 280 in-lb

15GV (0.127 mm) (0.127 mm) (3.22 kg-m)

20GL 0.005 in. 0.005 in. 420 in-lb

20GV (0.127 mm) (0.127 mm) (4.83 kg-m)

Thomas Type DBZ Coupling Specifications

Table 6. Thomas Type DBZ Coupling Specifications

Thomas Coupling End Gap Cover Bolt

Size Minimum Normal Maximum Torque

163 0.876 in. 0.938 in. 1.005 in. 156 in-lb

(22.24 mm) (23.81 mm) (25.41 mm) (1.80 kg-m)

201 0.876 in. 0.938 in. 1.005 in. 300 in-lb

(22.24 mm) (23.81mm) (25.41 mm) (3.46 kg-m)

226 1.126 in. 1.188 in. 1.251 in. 516 in-lb

(28.59 mm) (30.18 mm) (31.76 mm) (5.95 kg-m)

263 1.219 in. 1.313 in. 1.407 in. 756 in-lb

(30.97 mm) (33.35 mm) (35.73 mm) (8.72 kg-m)

301 1.406 in. 1.500 in. 1.594 in. 1140 in-lb

(35.72 mm) (38.10 mm) (40.48 mm) (13.15 kg-m)

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Thomas SN Spacer Type Vertical & Horizontal Coupling

Specifications
Table 7. Thomas SN Spacer Type Vertical & Horizontal Coupling Specifications

Thomas End Gap Operating Limits Bolt

Torque
Coupling Total Indicator

Size Reading

Minimum Normal Maximum Offset Angular

(Maximum) (Maximum)
SN226 0.563 in. 0.594 in. 0.625 in. 0.005 in. 0.005 in 516 in-lb
(14.30mm) (15.09mm) (15.88mm) (0.127mm) (0.127mm) (5.95 kg-m)

SN262 0.438 in. 0.469 in. 0.500 in 0.005 in. 0.005 in. 516 in-lb.
(11.13mm) (11.91mm) (12.70mm) (0.127mm) (0.127mm) (5.95 kg-m)

SN312 0.469 in. 0.500 in. 0.531 in. 0.005in. 0.005 in. 756 in-lb
(11.91mm) (12.70mm) (13.49mm) (0.127mm) (0.127mm) (8.72 kg-m)

Metastream Coupling Specifications

Table 8. Metastream Coupling Specifications

Metastream Distance Between Shaft Ends Operating Limits Bolt Torque

(ft-lb)
No. Total Indicator

Reading

Nominal Axial Misalignment* Lateral Misalignment**

TSE1-0075-XXXX-0032 0.125 in. ±.06 in. ±0.034 in. 22 ft-lb
(3.2mm) (±1.5mm) (±0.9 mm) (3.04 kg-m)

TSE1-0135-XXXX-0032 0.125in. ±.08 in. ±0.037 in. 48 ft-lb

(3.2mm) (±2.0mm) (±1.0mm) (6.64 kg-m)

TSE1-0230-XXXX-0048 1.220 in. ±.10 in. ±0.043 in. 77 ft-lb

(31.0mm) (±2.5mm) (±1.1 mm) (10.65 kg-m)

TSE1-0350-XXXX-0048 0.188 in. ±.11 in. ±0.048 in. 118 ft-lb

(4.8mm) (±2.8mm) (±1.2 mm) (16.32 kg-m)

TSRC-0075-XXXX-0030 0.118 in. ±.06 in. ±0.034 in. 22 ft-lb

(3.0mm) (±1.5mm) (±0.9 mm) (3.04 kg-m)

TSRC-0135-XXXX-0050 0.197 in. ±.08 in. ±0.037 in. 48 ft-lb

(5.0mm) (±2.0mm) (±1.0mm) (6.64 kg-m)

TSRC-0230-XXXX-0310 1.220 in. ±.10 in. ±0.043 in. 77 ft-lb

(31.0mm) (±2.5mm) (±1.1 mm) (10.65 kg-m)

* Meets NEMA end float specification without modification.

**Values based on angular deflection of 1/2° per end.

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Gearbox Lube Oil Specifications

Table 9. Gearbox Lube Oil Specifications

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Gearbox Parts List

Table 10. Gearbox Parts List

Item Part Name Qty. Item Part Name Qty.

No. No.

23A Lube Pump Spring 1 173 Tube (Sump) 1

51D Seal Rotating Face 1 174A Lube Jet 1

60C Mechanical Seal 1 174B Lube Jet 1

98 Dust Cover (For Coupled Shaft Only) 1 174C Lube Jet 1

101A Gearbox Housing (Output) 1 174D Lube Jet 1

101B Gearbox Housing (Input) 1 177 Valve 1

102 Bearing Plate 1 180 Filter Manifold 1

105** Housing Gasket 2 185 Oil Filter (FRAM PH-41) *1

110 Interconnecting Shaft 1 186 Fill and Vent Fitting 1

115 Shaft Seal *1 191 Sight Glass 1

A120 Low Speed Shaft Assembly 1 193C Pressure Gage 1

120 Low Speed Shaft 1 905E Hex Head Cap Screw 3

122A Spur Gear (Low Speed) 1 905H Hex Head Cap Screw 2

123A Shaft Spacer (Low Speed) 1 905M Hex Head Cap Screw 3

125C Ball Bearing *1 905N Hex Head Cap Screw 3

125D Ball Bearing *1 909B Bolt 7

A130 High Speed Shaft Assembly 1 909C Bolt (alignment) 2

130 High Speed Shaft 1 914E Hex Nut 7

132B Pinion Gear (High Speed) 1 914F Hex Nut (Alignment) 2

133B Thrust Runner 1 916A Washer 3

A140 Idler Shaft Assembly 1 916D Washer 2

140 Idler Shaft 1 916H Washer 14

122C Spur Gear (Idler) 1 961J Washer (alignment) 4

123B Shaft Spacer (Idler) 1 918D Pin 1

123C Shaft Spacer (Idler) 1 920A Key 1

125A Ball Bearing *1 920B Key 1

125B Ball Bearing *1 920C Key 1

132C Pinion Gear 1 920D Key 1

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Item Part Name Qty. Item Part Name Qty.

No. No.

151A Journal Bearing or Tilting Pad 1 920F Key (For Coupled Shaft Only) 1

Journal and Thrust Bearing 924AA Pipe Plug 1

Assembly (Lower) 924E Pipe Plug 1

151B Journal Bearing or Tilting Pad 1 924G Pipe Plug 1

Journal and Thrust Bearing 924H Pipe Plug 1

Assembly (Upper) 924K Pipe Plug 1

154D Lock Washer (Lower) 3 936AG** O-Ring 2

154E Lock Washer (Upper) 3 936K O-ring Packing 1

155A Thrust Washer (Lower) – required with 1 936M O-ring Packing *2

Journal Bearing

155B Thrust Washer (Upper) – required with 1 936N O-ring Packing *2

Journal Bearing
936T O-ring Packing *2

158 Shim Spacers AR 944a Pipe Connector (Female) 1

944b Pipe Connector (Male) 1

160 Lube Pump *1 947A Elbow 1

951Y Nipple 1
* Recommended Spare Parts
** Units built prior to January 2009 may have the housing gasket, item 105, in place of 936AG o-ring.

Gearbox Replacement Parts

Table 11. Gearbox Replacement Parts

Item No. Part Name Qty.

185 Gearbox Oil Filter 1

115 Input Shaft Lip Seal 1

105 / 936AG Housing Gasket / O-Ring 2

936M O-ring Packing 2

936N O-ring Packing 2

936T O-ring Packing 2

158 Series * Shim Spacers As Required

MP01AA10 Anti-fretting Compound Tube

*Available in sets of five 0.005 inch (0.13mm), 0.010 inch (0.25mm)

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Torque Specifications
Table 12. Gearbox and Pump Torque Values
Gearbox
Sundyne Standard Steel Screws & Bolts and NACE Compliant Steel Screws/Bolts (BG Material)
Torque Values
Item # Location Size English Metric
905H Oil Filter Manifold 3/8 - 16 x 1/2 22 - 25 ft-lbs 30 - 34 N-m
905L Gearbox Seal 1/4 - 20 x 1/2 75 - 80 in-lbs 8.5 - 9.0 N-m
905M, N Journal Bearings #10 - 24 x 1 35 - 40 in-lbs 4.0 - 4.5 N-m
905T Chemical Barrier Gasket 1/4 - 20 x 5/8 75 - 80 in-lbs 8.5 - 9.0 N-m
909B Gearbox Halves 1/2 - 13 x4 60 - 65 ft-lbs 81 - 88 N-m
909C Gearbox Halves, Alignment 5/8 - 18 x 4 17/64 60 - 65 ft lbs 81 - 88 N-m
906B Sight Glass #8 - 32 x 1/2 10 - 12 in-lbs 1.0 - 1.4 N-m
Pumps & Compressors*
Sundyne Standard Steel Screws and Bolts
Torque Values
Item # Location Size English Metric
3 Impeller Bolt/Inducer:
LMV/BMP-801, 802, 806, 322, 311, 331 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m
LMV/BMP-341, 346 1/2 - 20 65 - 70 ft-lbs 88 - 95 N-m
LMV-313, 343, BMP-338, 348 (High Flow) 3/4 - 10 85 - 90 ft-lbs 115-122 N-m
LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m
906D Diffuser Attaching Screws 1/4 - 20 95 - 102 in-lbs 11 - 11.5 N-m
905E Mechanical Seal No. Spacer 1/4 - 20 x 12 95 - 102 in-lbs 11 - 11.5 N-m
905F Throttle Bushing/Mechanical Seal 1/4 - 20 x 12 95- 102 in-lbs 11 - 11.5 N-m
905G Double Seal with Spacer 1/4 - 20 x 3/4 95 - 102 in-lbs 11 - 11.5 N-m
914A Case Nuts 3/4 - 10 250 - 275 ft-lbs 340 - 375 N-m
914A Case Nuts 7/8 - 9 300 - 330 ft-lbs 405 - 445 N-m
905A Seal Housing to Gearbox 3/8 - 16 x 1 3/4 35 - 40 ft-lbs 47 - 54 N-m
905P Separator 1/4 - 20 x 5/8 95 - 102 in-lbs 11 - 11.5 N-m
Pumps & Compressors
NACE Compliant Steel Screws / Bolts (BG Material)
Torque Values
Item # Location Size English Metric
3 Impeller Bolt/Inducer:
LMV/BMP-801, 802, 806, 322, 311, 331 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m
LMV/BMP-341, 346 1/2 - 20 65 - 70 ft-lbs 88 - 95 N-m
LMV-313, 343, BMP-338, 348 (High Flow) 3/4 - 10 85- 90 ft-lbs 115 - 122 N-m
LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m
906D Diffuser Attaching Screws 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m
905E Mechanical Seal No. Spacer 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m
905F Throttle Bushing/Mechanical Seal 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m
905G Double Seal with Spacer 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m
914A Case Nuts 3/4 - 10 160 - 200 ft-lbs 217 - 270 N-m
914A Case Nuts 7/8 - 9 225 - 245 ft-lbs 305 - 332 N-m
905A Seal Housing to Gearbox 3/8 - 16 x 1 3/4 27 - 30 ft-lbs 37 - 40 N-m
905P Separator 1/4 - 20 x 5/8 70 - 75 in-lbs 8.0 - 8.5 N-m
* When using Teflon® o-rings, allow 15 minutes between torquing for the Teflon® to cold flow. Repeat torquing until
there is no change in torque.
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Mechanical Seals
Table 13. Mechanical Seals

Item No. Description

Lower Upper Gearbox

Process Process Seal

Seal Seal

60A 60-B 60C Mechanical Seal Assembly

61A 61B 61C Seal Retainer

*62A 62B* *62C Seal Face Washer

*63A 63B N/A Seal Spring Backup Ring

*64A 64B* *64C Seal Retaining Ring

65A 65B* *65C Seal Spring

*68A 68B* N/A Teflon Wedge

*69A 69B* *69C Secondary may be “U” Cup

or o-ring

*Seal Repair Kits are Available and contain all parts marked with a
single asterisk.
Item 60C to be used on gearbox only.

To maximize seal performance consult the parts list for

correct seal configuration. For additional information, please
contact your area representative or the Sundyne factory
direct.

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1 ½” gas seal for upper tandem position on light hydrocarbon

service only

Gearbox Seal Only

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Pump Disassembly Replacement Parts

Table 14. Pump Disassembly Replacement Parts

The following replacement parts will be required as a result of pump

disassembly for maintenance as shown in this section:

Item No. Part Name Qty.

87A Thermal Barrier Gasket 1

RKORP311 O-ring Repair Kit for the

pump end consisting of:

936A • O-ring Packing

936D • O-ring Packing

936E • O-ring Packing

936F • O-ring Packing

936G • O-ring Packing

936H • O-ring Packing

936J • O-ring Packing

936K • O-ring Packing

936P • O-ring Packing

936V • O-ring Packing

936Z • O-ring Packing

See Seal Graphics Technical Seal Repair

Kits High Seal Rotating
faces:

51A • Single 1

51A/51B • Tandem 2

51C • Double 1

936B • O-ring Packing 1

936C • O-ring Packing 1

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Pumps Parts List

Table 15. Pump Parts List

Item Part Name Qty Item Part Name Qty

No. No.

1 Pump Casing 1 911 Stud 12

2 Impeller 1 914A Hex Nut 12

3 Impeller Bolt 1 916B Washer 3

4 Impeller Key *1 916S Washer 4

5 Impeller Tab Washer *1 918A Pin 1

9 Inducer (Optional) 1 924B Pipe Plug 1

10 Inducer Stud (Optional) 1 924D Bull Plug 1

13 Diffuser 1 936A O-ring Packing *1

14A Locating Pin 2 936B O-ring Packing *1

15 Diffuser Cover 1 936C O-ring Packing *1

21B Throttle Bushing 1 936D O-ring Packing *1

30 Seal Housing 1 936E O-ring Packing *1

50 Slinger Sleeve Assembly 1 936F O-ring Packing *1

51A Seal Rotating Face *1 936G O-ring Packing *1

51C Seal Mating Ring *1 936H O-ring Packing *1

87A Spacer (or Thermal Barrier 1 936J O-ring Packing *1

Gasket) (Large)

905A Hex head Cap Screw 3 981 Baffle Plate 1

905F Hex Head Cap Screw 3

* Recommended spare parts

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Single Seal Arrangement and Parts

Figure 12. Single Seal Arrangement

Table 16. Single Seal Arrangement

Item No. Part Name Qty. Item No. Part Name Qty.

21B Upper Throttle Bushing 1 905L Hex Head Cap Screw 3

50 Slinger Sleeve Assembly *1 916A Washer 3

51A Seal Rotating Face *1 916B Washer 3

51D Seal Rotating Face (Gearbox) *1 916K Washer 3

60A Mechanical Seal (Lower) *1 936H O-ring Packing *2

60C Mechanical Seal (Gearbox) *1 936J O-ring Packing *1

905E Hex Head Cap Screw 3 936K O-ring packing *1

905F Hex Head Cap Screw 3 936P O-ring Packing *1

*Recommended Spare Parts

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Double Seal Arrangement and Parts

Figure 13. Double Seal Arrangement

Table 17. Double Seal Arrangement

ITEM PART NAME QTY ITEM Part Name QTY

NO.
NO.
19A Seal Retaining Spacer 1 60B Mechanical Seal (Upper) *1
50A Shaft Sleeve (Lower) *1 61B - Retainer & Drive Sleeve Assembly 1
50B Shaft Sleeve (Upper) *1 62B - Seal Face Washer **1
51C Seal Rotating Face *1 63B - Seal Spring Back-Up Disc **1
51D Seal Rotating Face Gearbox *1
52 Seal Spacer 1 64B - Seal Retaining Ring **1
60A Mechanical Seal (Lower) *1 65B - Seal Spring **6
61A - Retainer & Drive Sleeve Assembly 1 68B - Seal Wedge Ring **1
62A - Seal FAce Washer **1 905G Hex Head Cap Screw 3
63A - Seal Spring Back-Up Disc **1 916B Washer 3
64A - Seal Retaining Ring **1 936H O-ring Packing *4
65A - Seal Spring **6 936J O-ring Packing *2
68A - Seal Wedge Ring **1 936K O-ring Packing *1
* Recommended Spare Parts
**Recommended Seal Spare Component Parts

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Tandem Seal Arrangement and Parts

Figure 14. Tandem Seal Arrangement

Table 18. Tandem Seal Arrangement

Item No. Part Name Qty. Item No. Part Name Qty.

21B Upper Throttle Bushing 1 905L Hex Head Cap Screw 3

50 Slinger Sleeve Assembly *1 916A Washer 3

51A Seal Rotating Face *1 916B Washer 3

51D Seal Rotating Face (Gearbox) *1 916K Washer 3

60A Mechanical Seal (Lower) *1 936H O-ring Packing *2

60C Mechanical Seal (Gearbox) *1 936J O-ring Packing *1

905E Hex Head Cap Screw 3 936K O-ring packing *1

905F Hex Head Cap Screw 3 936P O-ring Packing *1

*Recommended Spare Parts

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Separator Arrangements
Figure 15. Separator Arrangements

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Pump and Gearbox Cross Section (Single Seal Arrangement)

Figure 16. Pump and Gearbox Cross Section

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LMV-311 Gearbox (Exploded View)

Figure 17. 200 HP Gearbox.

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Pump Casing and Seal Housing (Exploded View)

Figure 18. Pump Casing and Seal Housing (Exploded View)

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Gaskets
Figure 19. Chemical Barrier Gasket (option)

Figure 20. Flexitallic Gasket (option)

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INDEX
Auxiliaries, 3 Maintenance, 20
Auxiliary Lube Pump, 5 Mechanical Seals, 74
Bearing and Shaft Clearances, 32 Minimum Flow Conditions, 18
BMP Units, 11 Mounting Vertical Units with Stands (LMV), 11
Check Driver Rotation, 4 Mounting Vertical Units Without Stands, 10
Check Operating Procedures, 5 Oil Manifolds, 13
Chemical Use, 3 Oil Pressure, 15
Control Checklist, 5 Operation of Sundyne Pumps, 18
Controlling the Pump During Startup, 17 Parallel Operation, 17, 19
Disassembly of LMV-311, 20 Personal Protective Equipment, 2
Double Seal Arrangement and Parts, 79 Piping Connections, 4
Driver and Coupling, 11 Pre-Commission Checklist, 3
Driver Instructions, 3 Pressurizing Fluid Loop, 5
Electrical Safety, 2 Preventative Machine Guards, 3
Entrained Gases, 18 Pump and Gearbox Cross Section (Single Seal
Environmental Control System, 4 Arrangement), 82
Equipment and Safety, 2 Pump Disassembly Replacement Parts, 76
Explosion/Fire Hazard, 3 Pump Mechanical Seal Diagnostics, 65
Falk Double Gear Type Specifications, 67 Pumps Parts List, 77
Falk Double Gear Type-Vertical Specifications, Reassembly, 33
68 Remote Heat Exchanger, 14
Falk Steelflex Type Coupling Specifications, 67 Seal Environmental Control System, 10
Fall Protection, 3 Separator Arrangements, 81
Flexible Coupling for LMV Units Without a Setting Pump Valves, 5
Vertical Stand, 12 Shaft Sleeve, 32
Gaskets, 85 Single Operation, 17
Gearbox, 14 Single Seal Arrangement and Parts, 78
Gearbox & Pump Diagnostics, 63 Specifications, 67
Gearbox and Pump Torque Values, 73 Start-Up Procedures, 16
Gearbox Heat Exchanger, 13 Storing Your Pump Long-Term, 8
Gearbox Lube Oil Specifications, 70 Storing Your Pump Short-Term, 8
Gearbox Mechanical Seal, 31 Suction and Discharge Piping, 9
Gearbox Parts List, 71 Suction Conditions, 18
Gearbox Replacement Parts, 72 SundGard Oil Filter, 14
Gearbox Servicing, 5 Sundyne Centrifugal Pumps, 1
Gearbox Sump, 14 System Head Curve, 18
Gearbox Sump Heater, 14 Tandem Seal Arrangement and Parts, 80
Heat Exchanger, 5 Testing Equipment, 2
High-Speed Shaft, 31 Text Symbols, 1
High-Speed Shaft Endplay, 61 Thomas SN Spacer Type-Vertical & Horizontal
Index, 86 Specifications, 69
Inspecting All Bearings, 31 Thomas Type DBZ Coupling Specifications, 68
Inspection, 8 Troubleshooting, 63
Inspection, Cleaning and Repair, 31 Using Forklifts, 2
INSTALLATION, 8
Installation and Start-Up Checklist, 6
ISO 9001, 2
Liquid Buffer System, 10
Lube System, 13
Machine Familiarization, 3
Main Lube Pump and Lube Oil Priming Kit, 15
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Sundyne Sundyne European Sundyne HMD Kontro Sealless Sundyne Marelli Pumps
Headquarters Headquarters Pumps Ctra. Madrid-Toledo, KM.30.8
14845 West 64th Avenue Sundstrand International S.A. Brampton Road 45200 Illescas
Arvada, Colorado 80007 13-15 Blvd.. Eiffel – B.P. 30 Hampden Park Industrial Estate Toledo, Spain
USA 21604 Longvic Cedex Eastbourne East Sussex, BN22 9AN
France Great Britain Phone: +34 925 53 45 00
Phone: (1) 303.425.0800 Fax: +34 925 51 16 00
Toll Free: 866-SUNDYNE Phone: +33 380 383300 Phone: +44 1323 452000
Fax: (1) 303.940.2911 Fax: +33 380 383366 Fax: +44 1323 503369
www.sundyne.com