I.O.M. 049-1806067-004 DND 150 DC13 PT RPP

DEWATERING & DREDGING PUMP
DnD 150 DC13

PT RPP CONTRATORS INDONESIA
PO No. POA/18/05/00084
I.O.M – INSTALLATION, OPERATION

AND MAINTENANCE MANUAL
PT KSB Indonesia
Head Office
Jalan Timor Blok D2-1, Kawasan Industri MM-2100
Cibitung, Jawa Barat 17520
Phone : +62 21 – 89983570
Fax : +62 21 – 89983571
www.ksb.co.id
Date 11.06.2018
DnD 150 DC13
Rev 00
INSTALLATION/OPERATING MANUAL
Pump DnD 150
WARRANTIES & COPYRIGHT
1. WARRANTIES replaced by KSB. No separate warranty shall apply
1.1 New Goods, if within a period of 12 months from to repair Goods as a whole or to parts not repaired
the date of delivery (or in the case of diesel- or replaced by KSB.
operated pumps, within the first 1,000 hours of 1.3 Exceptions, the warranties given by KSB in 1.1
operation, whichever first expires) (“warranty and 1.2 above do not cover:
period”) any new Goods sold by KSB (other than a) Fair “wear and tear”, or failures or damage not
purchased equipment as referred to in Clause 1.4) reported to KSB within the warranty period.
are found to be defective in materials or b) Failures or damage due to misapplication,
workmanship, or do not conform to any applicable abuse, improper installation or abnormal
drawings and specifications approved in writing by conditions of operation.
KSB, or (in the case of Goods which are KSB- c) Failures or damage due to operation, either
manufactured pumps) do not perform in intentional or otherwise, above or below rated
accordance with the current applicable water capacities or in an otherwise improper manner.
performance curves supplied as part of the KSB d) Failures or damage resulting from Goods which
quotation or published by KSB as at the date of the have been in any way tampered with or altered
quotation (within the tolerances specified in by anyone other than an authorized
applicable Australian Standards), then KSB will, at representative of KSB.
its option, either repair or provide replacement e) Goods damaged in shipment or without the fault
parts or Goods provided that: of KSB
a) The Purchaser has given written notice to KSB f) Failures or damage resulting from the
of any alleged defect within the warranty period; incorporation of, or failure of, non-KSB Mineral
b) The Purchaser has provided KSB a reasonable manufactured or supplied parts in the Goods.
opportunity to perform all appropriate tests on 1.4 Purchased Equipment, KSB does not warrant
the Goods; any equipment or other goods of other
c) The defective Goods or parts are promptly manufacturers which is designated by the
returned to a designated KSB service centre. Purchaser or purchased by KSB for resale to the
Any defective Goods or parts replaced will Purchaser either separately or as a part of or
become KSB property and the repaired or new operating in conjunction with equipment or other
Goods or parts will be delivered free to the goods manufactured by KSB. For such equipment
Purchaser’s site; and or other goods, the Purchaser must rely on the
d) No warranties are given by KSB as to the water warranty given by the manufacturer of the
performance of pumps other than in a test equipment or other goods.
facility designated by KSB. 1.5 Supply of Services, when KSB supplies Services
1.2 Repaired Goods, for repaired Goods, the to the Purchaser including laboratory testing,
warranty period is 6 months from the date of repair process development, equipment selection, design
and shall only apply to Goods or parts repaired or (as part of design and manufacture), detail,
i
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contract supervision and contract management, factors or on the whole installation or on the
KSB shall exercise due care and skill in individual or overall operation or on the skills
undertaking such Services. of an operator), whether made known or not
1.6 Limitation of Liability and any liability of KSB to compensate or
a) Subject to 1.6(b), KSB’s total liability under any indemnify any person or persons in respect
contract of which these General Conditions of of the foregoing, are expressly negative and
Sale form part shall in no event exceed the total excluded;
price of the Goods and/or Services supplied. ii. In no event shall KSB be liable for any
b) If any term, condition or warranty is implied into special, indirect, consequential, incidental or
these General Conditions of Sale by law, and punitive losses or damages whether in
cannot be excluded or modified, then the term, contract, tort (including without limitation
condition or warranty shall be deemed to be negligence), equity, under statute or on any
included in these General Conditions of Sale other basis, and whether or not such loss or
and the exceptions and limitations in 1.1 to 1.5 damage was foreseeable. The term
do not apply to such statutory rights and "consequential damages" in these General
remedies, Provided That KSB’s liability for a Conditions of Sale shall include, but not be
breach of any such term, condition or warranty, limited to, economic loss including loss of
including any consequential loss which the actual or anticipated profits, business
Purchaser may sustain, shall be limited, at the interruption, loss of use, revenue, reputation
option of KSB, to either replacing or repairing and/or data, increased cost of working, loss
the Goods or, in the case of Services, to or damage to equipment or other property,
supplying the Services again. and liabilities of the Purchaser to its
c) Subject to 1.6(b): customers or third persons.
i. All conditions, warranties, terms,
undertakings, representations and 2. INDEMNITIES
obligations, not expressly set out in these Subject to clause 1, the Purchaser indemnifies and
General Conditions of Sale or in any written holds KSB harmless from and against all liabilities,
contract of which these General Conditions losses, damages, costs or expenses incurred or
of Sale form part, whether arising under suffered by KSB and from and against all actions,
statute, common law, equity, custom, trade proceedings, claims or demands made against KSB,
usage or otherwise (including without arising in either case as a result of:
limitation, any implied condition, warranty, a) The Purchaser’s failure to comply with any laws,
term or representation as to the rules, standards or regulations applicable in relation
correspondence of the Goods or Services to the Goods or Services or the use of the Goods or
with any contract description or as to Services;
merchantable quality, fitness for any b) Any use of the Goods or Services contrary to any
purpose or safety of the Goods or Services, instructions or warnings given by KSB;
or operating performance where such c) Any other negligence or any breach of duty by the
performance is conditional on empirical Purchaser;
ii
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d) Any compliance or adherence by KSB with any representative, giving at least 5 days’ written notice
instructions by the Purchaser in relation to the (or such shorter period as may be agreed by KSB),
Goods or Services or their manner of preparation or and must be accompanied on such inspections by
delivery; or KSB personnel or other persons designated by
e) Any failures resulting from the incorporation of, or KSB.
failure of, non-KSB manufactured or supplied parts 4.2 Where practicable, KSB will subject Goods to
in the Goods. KSB’s standard tests before delivery. If tests other
than KSB’s standard tests are required, these,
3. DRAWINGS AND SPECIFICATIONS unless otherwise agreed, shall be conducted at
3.1 All descriptions, specifications, drawings and KSB’s nominated place of works or at some other
particulars of weights and dimensions attached to place nominated by KSB in its sole discretion and
or submitted with any quotation or tender are may at its option be charged for as extras. Any
approximate only and the descriptions and such charges will be payable by Purchaser within
illustrations contained in KSB’s catalogues, price- 30 days from the date of KSB’s invoice.
lists and other advertisement matter, are intended 4.3 If the Purchaser or its representative fails or is
merely to present a general idea of the Goods or unable to attend the tests after being given notice
the Services described therein, and none of these by KSB of not less than 7 days that it is ready to
shall form part of any contract between KSB and carry out the tests referred to in 4.1 and/or 4.2, the
the Purchaser. tests will proceed in the absence of the Purchaser
3.2 Only such descriptions, specifications, drawings or its representatives.
and particulars of weights and dimensions as are 4.4 The water performance of KSB-manufactured
specifically agreed by KSB in writing to form part of pumps in accordance with 1.1 above can be
the contract shall do so. The designs and verified where required by the Purchaser with
information concerning the Goods or the Services water performance tests carried out in a test facility
and as contained on any drawings which are designated by KSB. Additional charges and
supplied must not be disclosed to a third party delivery extension apply if this verification is
without KSB’s prior written consent. required.
4. INSPECTION AND TESTING 5. INTELLECTUAL PROPERTY RIGHTS

4.1 Representatives of the Purchaser approved by 5.1 KSB is the owner of certain patents and registered
KSB will be given access to KSB’s works or designs as well as other intellectual property rights,
another site designated by KSB during normal including, but not limited to, copyright (together the
office hours, for the inspection of the Goods and “Intellectual Property Rights”). KSB has also made
(subject to 4.2 and 4.3) for any testing of the certain applications for patents. The Purchaser
Goods which is specified in the scope of works must not directly or indirectly manufacture or
attached to or referred to in KSB’s quotation, in purchase from any third party the subject matter of
order to ensure compliance with specification. The the Intellectual Property Rights or the patent
Purchaser must make appointments for those applications, or in any way infringe the Intellectual
inspections through KSB’s nominated Property Rights or patent applications. The
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Intellectual Property Rights remain at all times the alleged infringement of any third party’s intellectual
exclusive property of KSB. property rights.
5.2 KSB retains ownership of the copyright and all 5.5 Where the Goods or the Services supplied are
other intellectual property rights in all drawings, designed by KSB and are found by a Court to have
manuals and other documents and materials breached a third party’s intellectual property rights,
provided to the Purchaser in connection with the KSB shall have the right to do such things as are
Goods and/or Services. The Purchaser may only necessary to remedy that breach.
use such documents and materials for its own
internal business purposes and to the extent 6. DISPUTE RESOLUTION
necessary for it to enjoy the benefit of the Goods 6.1 If any dispute arises between the Purchaser and
and/or Services, and may not disclose any of them KSB in relation to or in connection with a sale or
to any third party without the prior written consent supply of Goods or Services by KSB to the
of KSB, which may be granted or withheld in the Purchaser, they will use their best endeavors to
absolute discretion of KSB. resolve that dispute in a spirit of good faith and on
5.3 The Purchaser must keep confidential all a commercially realistic basis by mutual
information contained in all drawings, manuals and negotiation or by mediation prior to commencing
other documents and materials provided by KSB to litigation proceedings.
the Purchaser in connection with the Goods and/or 6.2 Any mediator shall be an independent person
Services, except to the extent that such chosen by the parties or, at their request,
information is in or come into the public domain nominated by the Local District Court. Each party
otherwise than through any act or omission of the shall bear its own costs. Any mediation shall take
Purchaser. It must only disclose such information place in Jakarta. The costs of the mediator shall be
to its employees, directors and advisers on a need- borne by the parties equally.
to-know basis. 6.3 If any dispute, controversy or claim has not been
5.4 Where and to the extent that the Goods or the resolved within 30 days after written notice from
Services ordered have been designed by the one party to the other giving details of the dispute,
Purchaser, the Purchaser is liable for and agrees controversy or claim, each party will be entitled to
to indemnify KSB against any and all costs, seek relief from an appropriate court.
expenses, liabilities and losses suffered or incurred
by KSB arising from any claims of infringement or
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PART I - INTRODUCTION
Pump DnD 150
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PART I
INTRODUCTION
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Original Equipment Manufacturer

Contact Details
For all information regarding your
“DEWATERING AND DREDGING (DnD) PUMP 200 DC16” Pump Set please
contact:
PT KSB Indonesia
(Head Office & Factory)
Jl. Timor Blok D2-1 Kawasan Industri MM 2100 Cibitung - Bekasi 17520
Tel. +62 21 89983570
Fax. +62 21 89983571
www.ksb.co.id
PT KSB Indonesia
(Balikpapan Representative Office)
Jl. Mulawarman No. 05 RT. 023 kel. Manggar - Balikpapan 76116
Tel. +62 542 771719, 771724
Fax. +62 542 771730
NOTE:
ALWAYS QUOTE UNIT MODEL AND SERIAL NUMBER WHEN
REQUESTING INFORMATION AND WHEN ORDERING PARTS
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1. INTRODUCTION
1.1. General
INFORMATION:
This manual contains important information for reliable, proper and

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

with during installation, operation and maintenance. Therefore this operating manual
must be read and understood both by the installing personnel and the responsible
trained personnel / operators prior to installation and commissioning, and it must always
be kept close to the operating location of the machine / unit for easy access. operating
instructions contain fundamental that must be complied with during operation and
maintenance. Therefore this operating manual must be read very carefully before you
start the pump unit or do any maintenance and service.
Not only must the general safety instruction given in this chapter of “safety” be
complied with, but also the safety instruction outlined under specific headings.
1.2.1. Safety Marking
Definition of safety symbols/markings.
INFORMATION
Use to draw your attention to important information that will facilitate

the work or operation
Indicates a hazardous situation which, if not avoided, could result

minor or moderate personal injury, minor or moderate equipment
damage
WARNING!
Indicates a hazardous situation which, if not avoided, could result

death or serious personal injury, major equipment damage
DANGER!
ELECTRICAL HAZARD
Indicates electrical danger
Instruction attached directly to the machine, such as:
 Arrow indicating the direction of rotation

 Marking for fluid connections must always be complied with and be kept in
legible condition at all times.
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1.2.2. Personnel Qualification and Training
All personnel involved in the operation, maintenance, inspection and installation of the
machine must be fully qualified to carry out the work involved.
Personnel responsibilities, competence and supervision must be clearly defined by the

operator. If the personnel in question are not already in possession of the requisite
know-how, appropriate training and instruction must be provided. If required, the
operator may commission the manufacturer/supplier to provide such training. In
addition, the operator is responsible for ensuring that the contents of the operating
instructions are fully understood by the responsible personnel.
1.2.3. Non-Compliance with Safety Instructions
Non-compliance with safety instructions can jeopardize the safety of personnel, the
environment and the machine itself. Non-compliance with these safety instructions will
also lead to forfeiture of any and all rights to claims for damages. In particular, non-
compliance can for example, result in:
 Failure of important machine/unit functions

 Failure of prescribed maintenance and servicing practices
 Hazard to person by electrical, mechanical or chemical effects
 Hazard to the environment due to leakage of hazardous substances.
1.2.4. Safety Awareness
It is imperative to comply with the safety instructions contained in this manual, the
relevant national and local health and safety regulations and the operator's own internal
work, operation and safety regulations.
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1.2.5. Safety Instructions for Operators

 Any hot or cold components that could pose a hazard must be equipped with the
guard by the operator.
 Guards that are fitted to prevent accidental contact with moving parts (e.g.
coupling) must not be removed while the machine is operating.
 Leakages (e.g. at the shaft seal) of hazardous media handled (e.g. explosive,
toxic, hot) must be contained so as to avoid any danger to persons and
environment. Pertinent legal provisions must be adhered to.
 Electrical hazards must be eliminated. (Refer to the relevant safety regulations
applicable to different countries and/or the local energy supply companies).
1.2.6. Safety Instructions for Maintenance, Inspection and Installation

 The operator is responsible for ensuring that all maintenance, inspection and
installation work is performed by authorized and qualified personnel who are
thoroughly familiar with the manual.
 Work on the machine must be carried out only during standstill. The shutdown
procedure described in the manual for taking the machine out of service must
be adhered to without fail.
 Pump units handling media injurious to health must be decontaminated.
 Immediately following completion of the work, all safety/protective devices
must be re-installed and/or reactivated.
 Please observe all instructions set out in the chapter on "Commissioning" before
returning the machine to service.
1.2.7. Unauthorized Modification and Manufacture of Spare Part
Modifications or alterations of the machine are only permitted after consolation with
the manufacturer. Original spare parts and accessories authorized by the manufacturer
ensure safety. The use of other parts can invalidate any liability of the manufacturer
for damage or warranty.
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1.2.8. Unauthorized Modes of Operations
Any warranty of the operating reliability and safety of the pump/unit supplied is only
valid if the machine is operated in accordance with its designated use as described in
the following sections. The limits stated in the data sheet must not be exceeded under
any circumstances.
1.2.9. Assembly and Disassembly Safety

 Dismantling and reassembly must always be carried out in accordance with the
rules of sound engineering practice and the relevant sectional drawings. Any
work on the motor, gear reducer, mechanical seal or other non-pump equipment
shall be governed by the specifications and regulations of the respective
supplier.
 Before assembly thoroughly clean all dismantled part mating surfaces and check
them for signs of wear. Damaged or worn components are to be replaced by
original equipment spare parts. Make sure that the seal faces are clean and the
o-rings and gaskets are properly fitted. It is recommended that new seal
elements (o-rings and gaskets) be used whenever the pump is reassembled. Make
sure that new gaskets have the same thickness as the old ones.
 Avoid the use of mounting aids as much as possible. Should a mounting aid be
required, use a commercially available contact adhesive. The adhesive should only
be applied at selected points (three to four spots) and in thin layers. Do not use
cyanoacryiate adhesives (quick-setting adhesives). If in certain cases mounting
aids or anti-adhesives other than those described are required, please contact
the sealing material manufacturer.
 The operator is responsible for ensuring that all maintenance inspection and
installation work is carried out by authorized, duly qualified staff who are
thoroughly familiar with these operating instructions.
 A regular maintenance schedule will help avoid expensive repairs and contribute
to trouble-free, reliable operation of the pump with a minimum of maintenance
expenditure.
 Repair and maintenance work to the pump must only be carried out by specially
trained personnel, using original equipment spare parts.
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 Work on the unit must only be carried out with the electrical
connections disconnected and locked out. Make sure that the pump
set cannot be switched on accidentally.
 Pumps handling liquids posing health hazards must be
decontaminated. When draining the medium ensure there is no risk
to persons or the environment. All relevant laws must be adhered
to.
 Before dismantling or reassembly, secure the pump so as to make

sure it cannot be switched on accidentally. The shut-off elements
in the suction and discharge nozzles must be closed. The pump
must have cooled down to ambient temperature, drained, and its
pressure must be released.
 Do not apply heat to the impeller hub or nose due to the sealed
cavity at the impeller nose. DANGER OF EXPLOSION!
 Upon completion of the work, all safety-related and protective
equipment must be properly refitted and/or reactivated before
DANGER! starting the pump set.
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PART II – TRANSPORT & STORAGE
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PART II
TRANSPORT &
STORAGE
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2. TRANSPORT & STORAGE

INFORMATION:
Pump set transport and storage instructions are intended as a guide

only. Site preparation, unit towing, and positioning to be undertaken
with regard to site conditions and procedures.
2.1. Transport
Proper lifting and safety practice must be observed at all times.

Lifting the pump unit requires extreme care, since the center of
gravity is not located in the physical center of the unit.
WARNING!
 Follow proper lifting practice and safety rules at all times, including:
 Verification of the lift weight and load rating of the lift equipment.
 Suitability and stability of the attachment points.
 In corrosive environments be sure to remove all lifting devices from the pump
and store in a non-corrosive environment until needed.
 Ensure that the pump is firmly strapped down during shipment. Pump should be
protected from direct contact with the elements.
 Always make sure that pump unit remains in the horizontal position during
transport and cannot slip out the transport suspension arrangement.
 If the pump/unit slips out of the suspension arrangement, it

may cause personal injury and damage to property.
 Do not use the pump/engine shaft as lift point. Eyebolt
locations on the bearing assembly and motor are intended
for lifting those items only and must not be used to lift the
pump unit.
 Do not place excessive side loads on cast lifting eyes. The
side loading angle on any lifting eye should not exceed 30
DANGER! degrees.
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Figure below give suggested lifting method. Actual safe lifting method will vary with
pump configuration and type of lifting equipment. Ensure secure attachment and test
lifting method for stability before moving pump unit.
Total dry weight for Pump Set up to ± 8500 kg!
WARNING!
LIFT
LIFT
Figure 2.1 Pump Set Lifting Method
Not recommended to Push or Pull pump set without Skid Runner,

it can cause damage.
DANGER!
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Figure below give suggestion to push pump set with pontoon into the sump. This method
is only used for pump set positioning to the sump not for moving. Ensure pump set
has mounted properly on skid runner.
Total dry weight for Pump Set with Pontoon up to ± 21000 kg!
WARNING!
PUSH AREA
Figure 2.2 Pump Set Position into The Sump

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2.2. Storage
The pump unit should be stored in a dry room where the atmospheric humidity is as
constant as possible. If stored outdoors, the unit must be covered by waterproof
material to avoid any contact with humidity. All openings of the assembled pump/unit
components are closed and must be opened when required during installation.
Protect all stored goods against humidity, dirt, vermin and

unauthorized access!!
WARNING!
2.2.1. Pump Storage
Pump should stored indoors and out of the weather until ready for installation, if it is
not available, cover the pump by waterproof material to avoid any contact with humidity.
 In freezing environments, water must be prevented from collecting

in the pump casing.
 For Oil Lubricated, pump shaft should be manually rotated
approximately 5 turns each month to keep the bearings coated.
 For Grease lubricated, bearing assemblies do not require monthly
rotation.
 The oil should be replaced if shutdown duration exceeds 12
months.
 After being idle to 1 or more months, oil analysis is recommended
for all pumps to ensure against condensation.
 Pumps with InPro/Seal® bearing isolators must be coated
externally with white grease or petroleum jelly to seal the gap
between the rotor and stator. Units equipped with a vent kit must
have the vents either removed and plugged, or blocked to prevent
air exchange.
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2.2.2. Driver Storage
Wherever possible, store the machine in a storage room. if it is not available, cover the
pump by waterproof material to avoid any contact with humidity.
 Covers or tarpaulins used to protect the equipment against the

weather must not make contact with the surfaces of the
equipment.
 Wrap the machine in plastic film to protect against humidity.
 Every three months, manually rotate the rotor through five
revolutions. Make sure that the resting position of the roller
bearings after the rotor has been turned is different from what it
previously had been.
 In storage up to six months, apply a coat of corrosion protective
compound to all accessible bare metal parts such as the exposed
shaft extension, flange or machine feet.
 In storage more than six months, apply a coat of anti-corrosion
compound which provides long-term protection. Remove the rotor
shipping brace, if one is being used. And, lubricate with twice the
grease quantity in accordance with the lubricant plate.
 Inspect the machine regularly. If needed, do maintenance work.
2.2.3. Vacuum Pump Storage
 In order to keep rubber parts and lip seals efficient and properly
working, we recommend to operate the pump for at least 30
minutes every 6 months with the intake closed.
 Store the pump in its packing in a covered, dry place at a
temperature between -20°C (-4 °F) and 50°C (122°F).
 If the vacuum pump is going to be stored without running from
time to time, protective measures must be taken. Consult to
Vendor.
2.2.4. Control Panel & Electrical Accessories Storage
 Control Panel & electrical accessories must be protected against

weather & humidity.
 Covers or tarpaulins used to protect the equipment against the
weather must not make contact with the surfaces of the
equipment.
 Wrap the machine in plastic film to protect against humidity.
 Inspect the machine regularly. If needed, do maintenance work.
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PART III – DESCRIPTION OF PRODUCT
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PART III
DESCRIPTION
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3. GENERAL DESCRIPTION
DEWATERING & DREDGING (DnD) PUMP unit have been designed and manufactured to
provide a better and more reliable alternative to efficiently pump clean the open mining
pits at the time. Pump set capable of pumping not only water against high head
conditions and handle coarse or fine particles from solids-laden waste water to
aggressive slurries of an abrasive or corrosive nature, but also large quantities of slurry.
Figure 3.1 DnD 150 DC13
GIW LCC Pumps is coupled with electric motor by flexible tyre coupling (direct
connection). They are mounted on heavy duty skid base frame that is integrated with
fuel tank storage. This Pump is also completed with automatic priming system with
electric control panel by auto-shutdown dry running protection. Full stainless steel
accessories in suction & discharge line to protect unit against corrosion. Roof canopy
available to protect engine and control panel.
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3.1. Pump Set Data Sheet
OWNER PT RPP CONTRACTORS INDONESIA

ADDRESS JL. Ciptomangukusumo No. 99 RT 26, Samarinda,
Kalimantan Timur 75131
ORDER NUMBER POA/18/05/00084
UNIT MODEL DnD 150 DC13
UNIT SERIAL NUMBER 049-1806067-004
BARE PUMP KSB LCC-H150-500.4K AF M1
BARE PUMP SERIAL NUMBER 9973578683-0500
BARE PUMP WET END MATERIAL HIGH CHROME WHITE IRON
BARE PUMP SHAFT SEAL GLAND PACKING
LUBRICATION OIL
DRIVER SCANIA DC13 074A
DRIVER SERIAL NUMBER 7104865
COUPLING TYRE COUPLING F180F
PRIMING SYSTEM KSB
BASE FRAME FAB. STEEL INTEGRATED
SUCTION LINE RUBBER HOSE WITH STRAINER
DISCHARGE LINE STAINLESS STEEL PIPING LINE WITH CHECK-
VALVE, DUTY & DRAIN VALVE
END FLANGE CONNECTION 14” JIS 10K
ACCESSORIES JIB CRANE, LIFTING BOOM & WINCH,
CONTROL PANEL & WORKING LAMPS, ROOF
CANOPY
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3.2. Pump Set Dimension & Mass
Length (exclude boom & suction hose)

Total Length ± 4500 MM
Width ± 3200 MM
Height ± 3100 MM
Pump Set Mass ± 8500 Kg
Pump Set w/ Pontoon ± 21000 Kg
3.3. Lubricant
RECOMMENDED
APPLICATION FREQUENCY CAPACITY REMARKS
LUBRICANT
ISO 150 Synthetic Oil
Pump Bearings 6 L Oil Bath
ISO 220 Mineral Oil Check Daily.
Engine SAE 15W 40 Top up if 48 L
required. PAO-based
Vacuum Pump ISO VG 68 3 L
vacuum pump oil
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PART IV
DETAILED OF
COMPONENTS
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4. DETAILED OF COMPONENTS
4.1. Bare Shaft Pump

4.1.1. Product Introduction
Figure 4.1 LCC-H150-500.4K
Centrifugal horizontal end suction pump type consists of semi-volute casing and three
vane impeller for large solid passage. High-chrome white iron material in wet end have
good wear characteristics to handled slurry.
The LCC pump range is an international product and has been designed, in most respects,
to the METRIC system of units using metric components. All fasteners are metric and
will require metric tooling. All seals are metric including oil seals, O-rings and stuffing
box packing.
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4.1.2. Pump Designation Code
“LCC-H150-500.4K AF M1”
CODE MEANS
LCC Pump Type
H Hydraulic Type M Metal
R Rubber
H Heavy Duty
200 Discharge Nozzle (mm) 50 80 100 150 200 250 300
610 Nominal Impeller Dia. 230 300 400 500 610 660 710
(mm)
5 Mechanical Size 1 35 mm
2 50 mm
3 70 mm
4 100 mm
5 125 mm
K Seal Type K KE
B Throat Bushing
M Mechanical Seal
E Expeller
AF Options O Open Shroud Impeller
AF Oil Lubricated – Face to Face
AB Oil Lubricated – Back to Back
UF Underwater Oil Lubricated – Face to Face
UB Underwater Oil Lubricated – Back to Back
GF Grease Lubricated – Face to Face
GB Grease Lubricated – Back to Back
T Turn Down Impeller
C Elastomeric Impeller
M1 Material Code M1 Metal
MC2 Metal / Chemical
R1 Rubber
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4.1.3. Pump Selection Chart
For used as a guide only. LCC’s are equipped with full-diameter impellers. Actual
operation speeds are obtained through V-belt drives, gear reducer, variable frequency
drive or other speed-changing drives.
Figure 4.2 LCC Family Curve

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4.1.4. Pressure, Sphere Passage & Temperature Limits
Figure 4.3 LCC Pressure, Sphere Passage & Temperature Limit
4.1.5. LCC Interchangeability
Figure 4.4 LCC Interchangeability

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4.1.6. LCC 150 Data Sheet
Material Suction Liner High Chrome White Iron, Gasite 28G(a)
Casing High Chrome White Iron, Gasite 28G(a)
Impeller High Chrome White Iron, Gasite 29G
Shaft 4150
Shaft Seal PTFE + Graphite
Shaft Sleeve Carbide Coated
Stuffing Box & Gland Class 40 Grey Iron
Padestal Class 40 Grey Iron
Bearing Housing Class 40 Grey Iron
Flange Standard Suction DN 200 ANSI B 16.5 Class 150
Discharge DN 150 ANSI B 16.5 Class 150
Max. Operation
16 bar
Pressure
Max. Pumping Speed 1700 rpm
Pump Rotation Clockwise (as seen from drive side)
Lubrication Oil
Note:
a) per ASTM Standard A532-93a, Class III, Type A.
For Detail please see: Part VIII DnD-03 LCC Maintenance Manual
4.1.7. Pump’s Recommended Spare Parts for Maintenance
Please see: Part VIII DnD-02 Pump Set Recommended Spare Parts
4.1.8. Bare Pump Curve
Please see next page

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4.2. Engine Driver
Figure 4.5 Engine Scania DC13 074A
The industrial engine type is a powerful, reliable and economical Versatile Diesel Engine
built on the dependable Volvo in-line six designs. Designed for the easiest, fastest and
most economical installation. Well balanced to produce smooth and vibration free
operation with low noise level, featured with high torque. To maintain a controlled
working temperature in cylinders and combustion chambers, the engine is equipped with
piston cooling. The engine is also fitted with replaceable cylinder liners and valve seats /
guides to ensure maximum durability and service life of the engine.
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Driver Specification:
Type Industrial Variable Speed Engine

Model DC13 074A
Power 331 kW @2100 rpm
Intake & Exhaust Turbocharged, Heavy Duty Air Cleaner, Exhaust Manifold, Muffler
System
Lubrication System Lubricating oil pump, oil cooler & filters
Fuel System Low pressure fuel pump
extra high pressure injectors System (XPI)
Cooling System Coolant pump, radiator include intercooler, fan (pusher type)
Control System Electronic governing, XPI
Starter Motor 24 VDC / 6 kW
Alternator 28 VDC / 100 A
Flywheel Housing SAE No. 1
Flywheel SAE No. 14
Accessories Base engine support, control panel
For Detail please see: Part VIII DnD-04 Engine Manual

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4.3. Flexible Tyre Coupling
Figure 4.6 Flexible Tyre Coupling
Martin-Flex couplings provide all the desirable features of an ideal flexible coupling,
including Taper Bush fixing. The Martin-Flex coupling is a “torsionally elastic’ coupling
offering versatility to designers and engineers with a choice of flange combinations to
suit most applications.
INFORMATION:
Tapper Bush Bore diameter are 125 mm (both sides)
The Coupling specification:
Brand Martin Type Martin-Flex
Coupling Size F180F Taper Bush No. 4535
Flex. Material Elastomeric Tyre Max. Bore 125 MM
Weight 42.2 Kg Temperature Range -50°C ~ 70°C
Misalignment Angle 4°
Parallel 1.1~6.6 mm
For detail please see: Part VIII DnD-05 Coupling

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4.4. Automatic Priming System
Battery
Figure 4.7 Automatic Priming System Diagram
DnD Priming System uses vacuum pump as the main components. Basic principle of
vacuum pump is with removing air from the enclosed system progressively decreases air
density within the confined space, thus causing the absolute pressure of the remaining
gas to drop. A vacuum is created. With pressure decreases in suction line (below than
atmosphere’s), water will flows toward vacuum tank and fill it until the level of water in
vacuum tank reaches “the level sensor”. This sensor will sent signal to panel to shut of
vacuum pump. To avoid water goes into the vacuum pump we put a water separator
between vacuum tank and vacuum pump.
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4.4.1. Vacuum Pump
Figure 4.8 Piston (Double Actings) Vacuum Pump
Ingersoll-Rand is two-stage, single acting, air-cooled vacuum pumps that do not require
installation on a special foundation. It can be furnished as a compact, self- contained,
receiver-mounted, automatic regulated and driven by coupled with bare pump shaft by
pulley. Double piston vacuum pump coupled by 12/24 Volt DC magnetic clutch which
working when priming is needed.
Vacuum pump specification:
Type V244
Bore Size 101.6 & 101.6
Stroke 69.85 MM
Speed 800 RPM
No. of Stage 1
Piston Displacement 32 CFM
Free Air Delivery 17.7 CFM
Max. Vacuum 0.98 BAR
Power Required 2.2 kW
Weight 140 KG
For detail please see: Part VIII DnD-06 Vacuum Pump Manual
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4.5. Electrical System
For detail please see: Part VIII DnD-07 Pump Set Wiring Diagram
4.6. Swing-Check Valve
Figure 4.9 Swing-Check Valve
Valve specification:
Type SISTO RSK-S
Body Material JS-1025 with with Rilsan coating
Disc Material Steel + IIR coating (soft rubber)
Max. Pressure 20 BAR
Permissible Temp. -20 °C – (+)120 °C
Flange Connection ANSI B16.5 CL150
Swing check valve SISTO RSK/RSKS mostly use in Mining Application to handled
abrasive liquid. This valve is designed with soft-seated in straight-way pattern and soft
rubber encapsulated disc with slanted sea.
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The Benefits of this valve are:
 Body geometry hydraulically optimized to provide low flow resistance

coefficient.
 The valve hydraulics without dead volume offers optimum condition for high-
purity fluids.
 The valve hydraulics without dead volume offers optimum condition for high-
purity fluids.
 Maintenance-free due to internal hinge pin.
 Soft rubber encapsulated disc provides reliable shut-off.
This swing check valve can be installed horizontally and vertically. Vertical installation is
only permitted if the fluid does not contain any solid and flow must be upward. The flow
direction must correspond to the arrow indicated on the valve body.
For detail please see: Part VIII DnD-08 Swing-Check Valve

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PART V
INSTALLATION
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5. PUMP SET INSTALLATION AT SITE

Electrical equipment operated in hazardous locations must comply with
the applicable explosion protection regulations. This is indicated on the
motor rating plate. If the equipment is installed in hazardous
locations, the applicable local explosion protection regulations and the
regulations of the test certificate supplied with the equipment and
issued by the responsible approval authorities must be observed and
complied with. The test certificate must be kept close to the location
WARNING! for easy access (e.g. foreman's office).
5.1. Foundation
All structural work required must have been prepared in accordance with the dimension
state in installation plan. The foundation shall have sufficient strength for the pump
unit and be completely fix before installation. The surface must be completely
horizontal and perfectly flat.
5.2. Mounting
Lifting of the pump set should be undertaken by experienced

personnel. Refer to site procedures for lifting, personnel and
equipment requirements.
DANGER!
After placing the base frame, it must be leveled by shimming. Shims should be fitted
between the base frame and the foundation itself; they should always be inserted to
the left and right of the foundation bolts and in close proximity to these bolts. For a
bolt to bolt clearance of more than 800 mm (30 in.), additional shims should be inserted
halfway between the adjoining holes. All shims must lie perfectly flush.
Figure 5.1 Fitting Shims

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5.3. Alignment
All components must be level during system operation. After attaching

the unit to the foundation and connecting the piping, the pump and
engine must be thoroughly checked and realigned.
WARNING!
Motor/Engine rotation’s direction must be checked before its shaft

coupled to pump’s shaft.
DANGER!
 Proper alignment must be taken into consideration. Engine feet must be firmly
supported at each mounting bolt location before the bolts are tightened. Shims
should be used to fill any gaps and ensure solid mounting and vibration
prevention.
 The correct distance between the coupling halves as specified in the installation
plan must be observed.
 The pump set is correctly aligned if a straightedge placed axially on both
coupling halves is the same distance from each shaft at all points around the
circumference. In addition, the distance between the two coupling halves must
remain the same all around the circumference. Use a feeler gauge, a wedge
gauge or a dial micrometer to verify.
INFORMATION:
Coupling Martin-Flex misalignment is 4° (angle) and 1.1 ~ 6.6 mm (parallel)
Use of the mounting bolts to close gaps between motor feet and the
mounting plate (in place of shimming) is not recommended and may
result in twisting of the motor frame, “soft foot” mounting and
DANGER! excessive vibration.
Improper alignment of the unit can cause damage to both coupling and
the unit itself.
DANGER!
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5.4. Installation Pump Set on Pontoon
Lifting of the pump set should be undertaken by experienced

DANGER!
Do not stand under suspended load! Do not place any part of body
under suspended load!
DANGER!
Check the pontoon for leakage before installing pump set!
WARNING!
Please follow instruction below for installation Pump Set on Pontoon:
 Make sure all materials below have been ready to installed;

 Pump Set
 Pontoon. All segments & accessories have completed (such as: handrails,
gantry & safety equipment)
 Bolts connection pump to pontoon (6 pcs of M16 or M20)
 Installation can be done at workshop or field area. It’s depending on site rules
and/or availability of lifting and transportation equipment.
 Make sure pontoon floating capacity meets with pump specification.
 The mountings surface must be flat, level and clean. There are six pump’s pads
mounting on pontoon surface.
 Lift pump set using proper lifting equipment and place above the pump pads on
pontoon.
 After placing pump set on the pontoon surface, it must be leveled by shimming.
Shims should be fitted between the pump base frame and foundation itself,
they should always be inserted to the left and right of the foundation bolts in
close proximity to these bolts.
 Torque the bolts mounting as specification.
 Mark the pontoon match with base frame dimension. It will make lifting or
maintenance operation easier in the future.
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Figure 5.2 Pump Set Position on Pontoon
5.5. Lifting Boom Installation
Installation of boom assembly should be undertaken by experienced

DANGER!
DANGER!
Please follow instruction below for installation of lifting boom:

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 Lifting boom
 Winch
 Wire Ropes, L= 3 meter, 2 pcs
 Shackles
 Boom pins
 Installation can be done at workshop or field area. It’s depending on availability
of lifting equipment.
 Lift lifting boom (1) using proper lifting equipment and install to boom bracket
(2) on pump base frame.
 Insert pins boom (3) and tighten the bolts.
 Pull wire rope from winch (4), through boom wheel (5).
 Using proper lifting equipment to pick up boom and lift into a position that will
allow the wire ropes (6) to reach the boom holder (7).
 Connect the wire rope using connecting shackles.
 Adjust tighten of each of two wire ropes using eye bolt.
4
6
Figure 5.3 Lifting Boom Installation

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5.6. Suction Line Installation
Installation of suction line should be undertaken by experienced

DANGER!
DANGER!
Figure 5.4 Suction Hose Installation

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Please follow instruction below for installation of suction line:

 Suction rubber hose, L= 5 meter
 Strainer
 Suction hose clamp
 Wire rope, L= 1 meter
 Bolts
 Installation can be done at workshop or field area. It’s depending on availability
of lifting equipment.
 Install suction hose clamp (1) on suction hose (2). Tighten the bolts.
 Install strainer (3) to suction hose. Tighten the bolts.
 Use wire rope of winch (4), pull it through the boom wheel and connect the hook
into suction hose clamp.
 Use proper lifting equipment to install suction hose to suction pipe. Tighten the
bolts.
 Pull winch to lift up the suction hose.
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5.7. Unit Positioning and Launching
Pump unit to be moved by experienced personnel only.
WARNING!
Pump unit moving and locating instructions are intended as a guide

only. Site preparation, unit towing and positioning to be undertaken
with regard to site conditions and procedures.
Before preparing the pump site, consideration must be given to the best pumping
location, with the aim at positioning the pump as near as possible to the deepest part of
the water catchment area.
5.7.1. Pump Site Preparation
Proper pump site preparation is important. It should provide a good approach for the
final positioning of the pump and allow access for fuel and service vehicles. Also, when
using a skid mounted pump in areas prone to flash flooding after heavy rainfall, quick
access to the unit maybe needed to tow it to safer ground.
For skid mounted pumps, the site should be prepared as close to the water as possible
and the final resting place of the pump should be reasonably level. Operating the pump
at an incline of over 10° is not recommended.
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5.7.2. Positioning and Launching

 Ensure that a suitable pump location is established which will provide a good
approach for final positioning and safe access for fuel and service vehicles.
 Skid mounted pumps should be positioned on level ground.
 Pumps should be positioned/launched using mobile crane, dozer or small
excavator.
 The operator must be able to see the point at center of the pump when lifted
unit. The equipment operator and person directing must be clear on the hand
signals being used by the person directing. Skid mounted pumps must only be
pushed on the push beam assembly provided.
Pontoon mounted pumps must only be pushed on the pontoon push bar,
and not on the pump skid.
WARNING!
 Before launching, consideration should be given to connecting customer’s

discharge lines. Final connections can then be done on land after the pump is
floating.
5.7.3. Pump Sitting Angle

5.7.3.1. Incorrect Pump Sitting Angle
 Pump Position is not on the flat ground.
 Discharge hose is kinked.
Figure 5.5 Incorrect Pump Sitting Angle

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5.7.3.2. Correct Pump Sitting Angle

 Pump Position is on the flat ground.
 Discharge hose curved where possible.
 Distance from Pump to Water Surface is no more than 4.5 Meter (based on duty
point) and suction hose depth is min. 6 x dia. hose.
Max. 4.5 M
Figure 5.6 Correct Pump Sitting Angle

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PART VI
OPERATION
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6. COMMISSIONING, START-UP AND SHUT DOWN
Compliance with the following requirement is of paramount importance.

Damage resulting from non-compliance shall not be covered by
warranty.
WARNING!
In compliance with the accident prevention regulations the pump must

not be operated without coupling guard.
DANGER!
Always using self protecting tools/device during working.
WARNING!
6.1. Preparation
Before starting up the pump unit, make sure that following requirement are checked and
fulfilled. The operating data, the oil level, the direction of rotation must be checked and
pump should be operated.
For detail please see: Part VIII DnD-09 Check List Pre-Commissioning for Pump.
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6.1.1. Pump Preparation

 Make sure all bolts mounting pump to skid have been tighten properly.
 Make sure level of bearing oil at the middle of sight glass.
 The impeller nose clearance has been properly set (0.25 mm).
You can see in Part VIII DnD-03 LCC Maintenance Manual for detail of
Impeller Nose Gap Setting.
 Make sure all pump accessories (such as RTDs, oil breather, stuffing box cover
& stuffing box drain line have been equipped properly).
 Rotate pump’s shaft manually (while alignment process). Make sure there is no
noise from impeller.
6.1.2. Driver Preparation

 Tightening all bolts mounting driver to skid.
 Check level of coolant in radiator.
 Check level of engine oil. Engine should be filled in with oil as recommended by
engine manufacturer (see on engine operating manual).
 Check fuel capacity in tank.
 Check cable connection has been installed properly.
 Check voltage of batteries is still good (24 volts).
6.1.3. Pump Set Preparation

 Check level of lubricant (pump & engine). Make sure the level reach min.
recommendation.
 Check level of coolant in engine radiator.
 Check fuel in tank.
 Check fuel engine hose inlet/outlet. Make sure no leakage on hose.
 Check connection cables to batteries have been tighten well & good condition.
 Check tightening bolts mounting for piping system, vacuum tank, vacuum line,
hoses, boom, roof & other accessories.
 Check instrument on control panel. Make sure the instrument is working.
 Check condition of boom and winch. Turn the handle at winch to up and down the
boom.
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 Check coupling alignment by remove coupling guard from skid, loosen the bolts at
coupling and remove the rubber coupling. Make sure coupling misalignment less
than 0.10 mm.
 Re-assemble the coupling installation after check the alignment and make sure
tightening bolts coupling is correct.
Maximum elevation angle of pump is 5 degrees.
WARNING!
6.2. Start-Up Preparation
Make sure these conditions below are fulfilled before starting up the
pump for both automatic and manual mode.
WARNING!
 Check the oil level of pump. It must at the middle of sight glass on oil tank.
 Check engine oil. Engine should be filled in with oil as recommended by engine
manufacturer (see on engine operating manual).
 Check level of coolant in engine radiator.
 Check fuel capacity in tank.
 Check voltage of batteries is still good (24 volts).
 Check there is no leakage of oil, fuel & coolant occur.
 Drain remains slurry/liquid from water separator & discharge pipe.
 Make sure strainer of suction hose is immersed under water. Minimum depth is 1
meter.
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6.3. Start-Up
Any damage due to manual operation will not covered under warranty.
DANGER!
Always using self protecting tools/device during working.
WARNING!
 Rotate battery switch “RED COLOUR” to ON position
 Make sure panel is working well without warning indicator or fault show up.
 Make sure all working lamps are working
 Rotate starter switch “YELLOW COLOUR” to ON position
 Make sure there is no Emergency Stop have been active

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 Make sure default setting below is fulfilled.
 Vacuum Mode : AUTO

 Booster Mode : OFF
 Push “Start” button to starting engine, pre-starting process will be take 2

seconds. And, there is idle time in 180 seconds.
 Make sure these condition below are fulfilled
INDICATOR ON/OFF
Engine Running Lamp ON
Vacuum Running Lamp ON
Low Level Lamp ON
Engine Fault Lamp OFF
Booster Mode Lamp OFF
Strobe Lamp ON
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 When pump has been filled by water, lamps indicator for vacuum run & low level
will turn off.
 After “idle time” reaches zero, increase the speed of engine slowly at duty point
required by rotate switch to the right side (to decreasing, rotate to left).
 Please see table of speed limitation below for guidance of pump operation.
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6.4. Check After Start-Up

 Check stuffing box leakage. Adjust gland follower tightness when there is too
much leakage.
 Check vibration or pump and driver.
 Check periodically pump’s bearing temperature. Unit must be shut off if bearing
temperature reaches 120oC.
 Check periodically engine parameter (coolant temp/level, oil temperature, fuel
pressure and battery voltage)
 Check periodically panel temperature.
 Check periodically for leakage of fuel/oil or water at hose/pipe connection.
6.5. Shut Down

 Reduce the driver speed to 650~700 rpm (low idle speed). Keep ± 1 minute.
 Turn off the driver.
 After all electrical devices completely off, drain discharge pipe.
 Drain slurry/liquid in water separator.
 When pumping heavy mediums it is advisable to raise the pumps strainer into
clean water prior to shutting down to prevent slurry from settling in the pumps
casing.
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6.6. Troubleshooting
6.6.1. Low Flow Rated
 Verify that the pump is correct for the system parameters in terms of flow and
head. The pump curve can be used to determine the output, power and speed.
 Depending on the operating time and service of the pump, parts could be worn
sufficiently and reduce performance.
 Verify that the pump is running at the correct speed.
 Verify that suction side has adequate NPSH as outlined in the pump
specification.
 Check the suction pipe for air pocked, leaks; partially closed valves or other
restriction.
 Be certain that the suction inlet and impeller are not clogged.
6.6.2. Pump Fail to Prime

 Check Vacuum pump, whether it is running or not.
 If the vacuum pump was not working, check electric current that power up
magnetic clutch.
 If the vacuum pump is running well then check strainer for solid slurry, dirt that
might obstruct liquid from entering the suction hose.
Water Surface
Check for
Debrish
Figure 6.1 Strainer Clogging
 Check connection of suction line from leakage.

 Clean up magnetic clutch from dirt, slurry, dust if you find it run on slip.
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Figure 6.2 Leakage Critical Area
 Check part inside check valve, wear part may cause leakage and reduce vacuum
condition.
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PART VII
PARTS LIST
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7. PARTS LIST
7.1. Bare Pump & Accessories
2
3
6
5
8
4
NO PART NUMBER DESCRIPTION QTY UoM

1 PP056000323-3 LCC-H150-500.4K AF M1 1 Unit
2 PS0560057L Stuffing Box Cover LCC 150, SS304 1 Set
3 PA00010112 PT100 1 Pc
4 PA05608194-5 Rubber Hose 2", 5 Bar, L= 3 Meter 1 Pc
5 BLT-UNC 1-002 Hex. Bolt 1"-8 UNC, Grade 8, L= 3", with W'Spring 6 Set
6 CMS000079 Air Breather Filter 1 Pc
7 PA05600085 Cover Radial Bearing Housing LCC 150, SS304 1 Set
8 PA05600165-2 Stuffing Box Drain Pipe, DnD 150, SS304 1 Pc
CMS000138 SHELL MORLINA S2 B 220 1 Pail
1 Pail = 20 Liter
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7.2. Bare Pump Spare Parts
Please see next page.

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7.3. Engine & Accessories
4 3 1 2

1 PA00005035-1 Engine Scania DC13 074A, 331 kW @2100 rpm 1 Unit
2 PA00002346 Flex Coupling F160F, Bushing Bore 100 x 100 mm 1 Set
3 PA00006007 Accu 12V/200A, Maintenance Free 2 Unit
3 PA00002473-A BATTERY BOX, 2 X 200A/12V DRY TYPE, NEW 1 Set
4 PA05606064-3 Fuel Tank KIT, DnD 200 Volvo 1 Set
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7.4. Coupling & Coupling Guard

2

1 PA00002346 Flex Coupling F160F, Bushing Bore 100 x 100 mm 1 Set
2 PA05602023-2 COVER COUPLING DnD 150 VOLVO, 2017, 01 1 Set
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7.5. Priming System
6 7
4 5
2 9
1
10
11

1 PA00010110 Level Sensor, FineTek SC281L0TACR, 24VDC 2 Set
PA00000021 O-ring 2 Pcs
2 PA05608080-J Vacuum Tank 10", SS304 1 Set
3 CMS011522-2 Pressure Gauge -1 ~ 1.5 Bar, Back Mounted 1 Pc
4 BLV00014L Ball Valve 1/2” 1 Pc
5 PA05600129-1 Rubber Hose 1/2" 4 Meter
6 PP1110001L Vacuum Pump V244, Ingersollrand 1 Unit
7 PA00002150-A Guard, Coupling Shaft Magnetic Clutch, DnD 1 Set
7 PA00002150 Coupling Shaft Magnetic Clutch 1 Pc
8 PA00002488 Magnetic Clutch Borelli 24 VDC c/w Pulley SPA 12" 1 Unit
9 PA00002746 V-belt SPA 2000 2 Pcs
10 PA05602019 Pulley ID 125MM, OD 185MM, 2 grovees 1 Set
11 PA05608080-F1 SUPPORT FOR VACUUM PIPE 10" 1 Set
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7.6. Suction & Lifting Boom Assembling
5
4
2
1

1 PA05612002-3 Strainer 8" w/ SS Chain 1 Set
2 CMS1110-2 Suction Rubber Hose 8", L= 5 M 1 Unit
3 PA05608005-2 Single Clamp for Hose 8", Hot Dipped Galvanized 1 Set
3 CMS000115-7B STEEL WIRE ROPE Dia. 8 MM, WLL 850 KG, L= 1 1 Pc
METER WITH THIMBLE LOOP EACH END
3 PA05610008-1 SCREW PIN CHAIN SHACKLE, SIZE 3/8", WLL 1 2 Pcs
TON, GALVANIZED
4 PA05603082-4 Boom Lifting, DnD Pumps, Pipe Design, L= 5 Meter 1 Unit
4 CMS000115-7 STEEL WIRE ROPE Dia. 8 MM, WLL 850 KG, L= 3 2 Pcs
METER WITH THIMBLE LOOP EACH END
4 PA05610008-1 SCREW PIN CHAIN SHACKLE, SIZE 3/8", WLL 1 4 Pcs
TON, GALVANIZED
5 PA05600093-1 MANUAL WINCH 800 KG, BRAKE SERIES 1 Unit
5 PA00002437-1 Wire Rope Dia. 1/4" (6.4 MM), L= 15 M, with Thimble 1 Pc
"Hook"
5 PA05600093-1A WINCH COVER, 800 KG 1 Set
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7.7. Discharge Line

7
1 2 3

1 - Elbow 90° - 6” with Flange ANSI CL150 1 Set
2 CHV016P0801100900033 Swing Check Valve 6” 1 Unit
3 PA05603045-3 Support Pipe 6", DnD 150 2 Set
4 CMS0169-3 U-Clamp for Pipe 6”, Hot Dipped Galvanized 2 Pcs
5 - Pipe 6” with Flange ANSI CL150, L= 2500 mm 1 Set
6 BLV100004091064100L Ball Valve 2” 1 Unit
7 BFV016P0806102514019 Butterfly Valve 6” 1 Unit
8 - Increaser Pipe 6” ANSI CL150 to (as per 1 Set
customer request)
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7.8. Other Accessories

4 5
1 6
10

1 CMS000236-3 Manual Chain Hoist c/w Geared Trolley 500 Kg 1 Unit
2 PA05603181-4 Jib Crane, DnD/LSA Pump 1 Set
3 PA05603021-5B ROOF CANOPY ASSY, DnD 150 1 Set
4 CMS000270-3 Strobe Lamp LED 24 VDC, Blue 1 Unit
5 CMS012233-2 BEAM LAMP, LED, 27 WATT, 9-30 VDC, IP68 3 Unit
6 PA056070792 Panel control system DnD Engine Scania 1 Unit
7 PA05603142-5A Front Pillar, DnD 150 , Single Lifting, Ver_01 1 Set
8 PA00010037-1 Pressure Gauge 0~16 Bar, Diaphragm 1 Unit
9 PA05603142-5B Rear Pillar, DnD 150 1 Set
10 PA00007555-2 LOTO Box Assy 1 Set
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PART VIII – MANUALS & DRAWINGS
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PART VIII
ACCOMPANYING
MANUALS &
DRAWINGS
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DnD-01
GENERAL
ARRANGEMENT
DRAWING
0123426178
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DnD-02
PUMP SET
RECOMMENDED
SPARE PARTS
LCC-H150-500.4K AF M1 (DnD 150)
PART CONSUMPTION FOR PERIODIC MAINTENANCE
No PART ID NUMBER DESCRIPTION QTY UOM
Initial Service (50 - 100 hours)
1 CMS000138 Oil Shell Morlina S2 B 220 3 L
Note: Syntethic Oil ISO150 or Mineral Oil ISO220/320
250 Hrs Maintenance Items

1 PS0560038L-3 Gland Packing LCC 150, PTFE 1 Set
Note: Length per ring is 592.6 mm

2 CMS000138 Oil Shell Morlina S2 B 220 3 Liter
1 PS0560040L SHAFT SLEEVE 100X125X167.5MM, LCC 150, WC200 1 PC
2 PS056004623 Gasket Kit,Shaft Sleeve, 100MM, P/N.99-9 1 SET
3 PS056004723 Gasket Kit, Wet End, LCC20 (METAL), P/N.99-9 1 SET
4 PS056009023 Lantern Ring, 125MM , P/N.458 1 SET
2 CMS000138 Oil Shell Morlina S2 B 220 3 Liter
3 PS0560040L SHAFT SLEEVE 100X125X167.5MM, LCC 150, WC200 1 PC
4 PS056004623 Gasket Kit,Shaft Sleeve, 100MM, P/N.99-9 1 SET
5 PS056004723 Gasket Kit, Wet End, LCC20 (METAL), P/N.99-9 1 SET
6 PS056009023 Lantern Ring, 125MM , P/N.458 1 SET
7 PS056038823 BEARING LOCK WASHER 1 Ea
8 PS056038923 BEARING LOCK NUT 1 Ea
9 PS056039123 GASKET KIT, CBA 1 Set
10 PS056004423 Inpro Seal, 100MM CBA, P/N.420.50 1 Ea
11 PS056004523 Inpro Seal, 100MM, P/N.420.70 1 Ea
RECOMMENDATION PARTS STOCK FOR 2 YEAR OPERATION

No PART ID NUMBER DESCRIPTION QTY UOM
1 PS056004923 SUCTION LINER, 8LCC20 (XH) 1 PC
2 PS0560020L Stuffing Box LCC-H150-500.4K, CD4MCu 1 PC
3 PS0560077L Gland LCC150, SS304 1 SET
4 PS056004223 RADIAL BEARING 1 PC
5 PS056038723 THRUST BEARING 1 SET
6 PA00002346 Flex Coupling F160F, Bushing Bore 100 x 100 mm 1 SET
7 PA00010110 Level Sensor Finetek 2 UNIT
8 PP1110001L Vacuum Pump - Ingersollrand - V244 Bare Pump 1 UNIT
9 PA00002488 Magnetic Clutch Borelli 24 VDC dia.pulley 12" 2 UNIT
10 CHV016P0801100900033 Swing Check Valve SISTO RSK-S; PN16; DN150, Body JS-1025 1 UNIT
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DnD-03
LCC
MAINTENANCE
MANUAL
Installation/Operating Manual
05/2014 LCC
LCC – Metal LCC – Rubber
Pump Type:
Pump Serial Number:
Date:
Purchaser:
Purchaser’s Order Number:
GIW Work Order Number:
Shipped To:
Include the pump’s serial number when ordering replacement parts

This is a standard maintenance manual provided for your convenience
This manual may include additional documentation not applicable to your specific pump
GIW INDUSTRIES, INC. KSB AG

5000 Wrightsboro Road Johann-Klein-Str. 9
Grovetown, GA 30813 USA D-67227 Frankenthal, Germany
+1 (888) 832-4449 +49 6233 86-0 .
FAX +1 (706) 855-5151 FAX +49 6233 86-3289
www.giwindustries.com www.ksb.com
LCC
Legal Information/Copyright
Installation/Operating Manual LCC

Original operating manual (English)
In case of conflict between the local language version and the original operating manual, the original operating manual prevails.
All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other
purpose, nor otherwise transmitted, published or made available to a third party without KSB´s express written consent.
Subject to technical modification without prior notice.
© GIW Industries, Inc. 05.2014
2
LCC
Contents
Section Page Section Page
6.4.3 Density of the Medium Handled 24

1 General 5 6.5 Underwater Pump Operation 24
2 Safety 6 7 Maintenance 26
2.1 Safety Markings 6 7.1 Supervision of Operation 26
2.2 Personnel Qualification and Training 6 7.2 Drainage / Disposal 26
2.3 Non-compliance with Safety Instructions 6 7.3 Lubrication and Lubricant Change 26
2.4 Safety Awareness 7 7.3.1 Underwater Operation 27
2.5 Safety Instructions for Operators 7 7.4 Procedures for Maximum Parts Life 27
2.6 Safety Instructions for Maintenance, Inspection & 7.5 Operational Problems and Solutions 27
Installation 7
2.7 Unauthorized Modification and Manufacture of 8 Mechanical End 29
Spare Parts 7 8.1 Mechanical End Overview 29
2.8 Unauthorized Modes of Operation 7 8.2 Mechanical End Disassembly 29
2.9 Assembly & Disassembly Safety 7 8.3 Mechanical End Assembly 30
8.3.1 Mounting the Bearings 30
3 Transport and Storage 9 8.3.2 Back to Back Thrust Bearing Installation 31
3.1 Transport & Handling Safety 9 8.3.3 Face to Face Thrust Bearing Installation 32
3.2 Storage Requirements 10 8.3.4 Installing End Covers and Seals 33
3.2.1 Storage of New Pumps – Pumps under Warranty 10 8.4 Bearing Assembly Mounting 34
3.2.2 Pump Storage 10
3.2.3 Pump Parts Storage 11 9 Shaft Seal 35
3.2.4 Removal from Storage 12 9.1 Mechanical Seal 35
3.3 Recommended Lifting 13 9.1.1 Mechanical Seal Assembly and Disassembly 35
9.2 Stuffing Box 35
4. Description 14 9.2.1 Stuffing Box Packing 36
4.1 Technical Specification 14 9.2.2 Stuffing Box Assembly 36
4.2 Designation 14 9.2.3 Stuffing Box Maintenance 36
4.3 Design Details 14 9.3 Expeller Seal 38
4.4 Noise Characteristics 14 9.3.1 Expeller Assembly 39
4.5 Accessories 14 9.3.2 Expeller Disassembly 39
4.6 Dimensions and Weights 15 9.3.3 Expeller Running Clearance 40
4.7 Forces and Moments at Nozzles 16
10 Wet End 41
5 Installation at Site 17 10.1 Wet End Overview 41
5.1 Safety Regulations 17 10.1.1 Pump Casing 41
5.2 Foundation 17 10.1.2 Impeller Form 41
5.3 Installing the Baseplate and Pump 17 10.2 Wet End Disassembly 41
5.3.1 Aligning the Pump / Drive Train for Horizontal 10.2.1 Impeller Removal 41
Pump Application 17 10.2.2 Impeller Break-Loose Jig 42
5.3.2 Place of Installation 18 10.2.3 Impeller Lifting Jig 42
5.4 Connecting the Piping 18 10.2.4 Casing Removal 42
5.4.1 Auxiliary Connections 19 10.2.5 Elastomer-Liner Removal 42
5.5 Safety Guards 19 10.3 Wet End Assembly 42
5.6 Oil Temperature Monitoring (RTD) 19 10.3.1 Mounting the Shaft Sleeve 42
5.7 Final Check 19 10.3.2 Mounting the Casing 43
5.8 Connection to Power Supply 19 10.3.3 Elastomer Lined Wet End 43
6 Commissioning, Startup and Shutdown 20 10.3.4 Installing the Impeller 43
6.1 Commissioning / Return to Service 20 10.3.5 Suction Plate & Liner (LCC-H only) 43
6.1.1 Bearing Lubrication 20 10.4 Setting the Nose Gap 44
6.1.2 Shaft Seal Commissioning 22 11 Tooling 46
6.1.3 Checking the Direction of Rotation 22 11.1 Torque Requirements 46
6.1.4 Cleaning the Plant Piping 22 11.2 Spare Parts Stock 47
6.1.5 Suction Strainer 22
6.2 Startup 23 12 Troubleshooting 48
6.2.1 Priming the Pump 23
6.3 Shutdown 23 13 Supplements 49
6.3.1 Measures to be taken for Prolonged Shutdown 24 13.1 Duo Cone Seals 49
6.4 Operating Limits 24 NOTES 51
6.4.1 Temperature Limits 24
6.4.2 Switching Frequency 24 General Drawing with List of Components 52
3
LCC
Index
Section Page Section Page
Accessories 4.5 14 Operational Flow & Head 7.5 28

Alignment 5.3.1 17 Operational Problems and Solutions 7.5 27
Assembly Safety 2.9 7 Packing 9.2.1 37
Assembly, Wet End 10.3 43 Parts Life 7.4 27
Assembly. Mechanical End 8.3 31 Personnel 2.2 6
Auxillary Connections 5.4.1 19 Piping System Design 7.5 28
Baseplate 5.3 17 Piping, Allowable Forces and Moments 4.7 16
Bearing Assembly Clamp Bolts 8.4 35 Piping, Cleaning 6.1.4 22
Bearing Assembly Mounting 8.4 35 Piping, Connecting 5.4 18
Bearings Installation 8.3.1 31 Power Supply 5.8 19
Bearings Lubrication, Commissioning 6.1.1 20 Priming the Pump 6.2.1 23
Casing Installation 10.3.2 44 Pump Description 4 14
Casing Removal 10.2.4 43 Pump Design Details 4.3 14
Casing, Parts Life 7.4 27 Pump Designations 4.2 14
Casing 10.1.1 42 Pump Specification 4.1 14
Cavitation / NPSH Performance 7.5 28 RTD Installation 5.6 19
Commissioning / Return to Service 6.1 20 Safety Awareness 2.4 7
Commissioning, Bearing Lubrication 6.1.1 20 Safety Guards 5.5 19
Commissioning 6 20 Safety Markings 2.1 6
Density of the Medium Handled 6.4.3 24 Safety, Final Check 5.7 19
Dimensions 4.6 15 Safety, Non-compliance 2.3 6
Direction of Rotation 6.1.3 22 Safety, Operators 2.5 7
Disassembly Safety 2.9 7 Safety, Regulations 5.1 17
Disassembly, Mechanical End 8.2 30 Safety, Transport & Handling 3.1 9
Disassembly, Wet End 10.2 42 Safety 2 6
Drainage / Disposal 7.2 26 Seal Water Requirements 9.2.3 37
Drawings 53 Shaft Seal, Commissioning 6.1.4 22
Elastomer Wet End Installation 10.3.3 44 Shaft Seal 9 36
Elastomer Wet End Removal 10.2.5 43 Shaft Sleeve, Mounting 10.3.1 43
End Covers and Seals Installation 8.3.4 34 Shutdown, Prolonged 6.3.2 24
Expeller Running Clearance 9.3.3 41 Shutdown 6 20
Expeller Seal Assembly 9.3.1 40 Shutdown 6.3 23
Expeller Seal Disassembly 9.3.2 40 Spare Parts Stock 11.2 48
Expeller, Maintenance 7.4 27 Spare Parts, Unauthorized Modification 2.7 7
Expeller 9.3 39 Startup 6 20
Foundation 5.2 17 Startup 6.2 23
Impeller Installation 10.3.4 44 Storage Requirements 3.2 11
Impeller Removal, Break Loose Jig 10.2.2 43 Storage, Pumps Under Warranty 3.2.1 10
Impeller Removal, Lifting Jig 10.2.3 43 Stuffing Box Assembly 9.2.2 37
Impeller Removal 10.2.1 42 Stuffing Box Maintenance 9.2.3 37
Impeller, Parts Life 7.4 27 Stuffing Box Packing 9.2.1 37
Impeller 10.1.2 42 Stuffing Box, Commissioning 6.1.2 22
Inspection, Safety 2.6 7 Stuffing Box 9.2 36
Installation, Location 5.3.2 18 Suction Liner, Parts Life 7.4 27
Installation, Safety 2.6 7 Suction Plate & Liner Installation ( LCC-H Only) 10.3.5 44
Installation 5 17 Suction Strainer 6.1.5 22
Lifting 3.3 13 Sump Design 7.5 27
Lubricant Change 7.3 26 Switching Frequency 6.4.2 24
Maintenance Equipment 11 47 Temperature Limits 6.4.1 24
Maintenance, Safety 2.6 7 Thrust Bearing Installation (Back to Back) 8.3.2 32
Maintenance 7 26 Thrust Bearing Installation (Face to Face) 8.3.3 33
Mechanical End Assembly 8.3 31 Tooling 11 47
Mechanical End Disassembly 8.2 30 Torque Requirements 11.1 47
Mechanical End 8 30 Transport, Storage & Handling 3 9
Mechanical Seal Assembly & Disassembly 9.1.1 36 Troubleshooting 12 49
Mechanical Seal, Commissioning 6.1.2 22 Underwater Operation 7.3.3 27
Mechanical Seals 9.1 36 Underwater Pump Operation 6.5 24
Noise Characteristics 4.4 14 Wear Problems and Solutions 7.5 27
Nose Gap Adjustment 10.4 45 Weights 4.6 15
Oil Temperature Monitoring 5.6 19 Wet End Assembly 10.3 43
Operating Limits 6.4 24 Wet End Disassembly 10.2 42
Operation, Unauthorized Modes 2.8 7 Wet End 10 42
4
LCC
1 General
CAUTION
This manual contains important information for reliable, proper and efficient operation. Compliance with the
operating instructions is of vital importance to ensure reliability and long service life of the pump, and to avoid
any risks.
These operating instructions do not take into account local regulations; the operator must ensure that such regulations are
strictly observed by all, including the personnel called in for installation.
WARNING
This pump / unit must not be operated beyond the limit values specified in the technical documentation for the
medium handled, capacity, speed, density, pressure, temperature and motor rating. Make sure that operation
is in accordance with the instructions given in this manual or in the contract documentation.
The nameplate indicates the type series / size, main operating data and serial number. Please quote this information in all
queries, repeat orders and particularly when ordering spare parts.
This manual may contain information not applicable to your pump/unit. Your pump/unit may not be equipped with all features
or auxillary components as described in this manual. Consult your pump/unit drawings and Bill of Materials for details.
If you need any additional information or instructions exceeding the scope of this manual or in case of damage, please contact
your GIW / KSB representative.
5
LCC
2 Safety
These operating instructions contain fundamental information that must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read and understood both by the installing personnel and the
responsible trained personnel / operators prior to installation and commissioning, and it must always be kept close to the
operating location of the machine / unit for easy access.
Not only must the general safety instructions given in this chapter of “Safety” be complied with, but also the safety instructions
outlined under specific headings.
2.1 Safety Markings

Definition of safety symbols/markings
Symbol Description
DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury
WARNING
WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious
injury.
CAUTION
CAUTION This signal word indicates a hazard which, if not avoided, could result in damage to the machine and its
functions.
Explosion protection
This symbol identifies information about avoiding explosions in potentially explosive atmospheres in
accordance with EC Directive 94/9/EC (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a hazard which will or could result in
death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and
identifies information about protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its
functions.
Instructions attached directly to the machine, such as:

 Arrow indicating the direction of rotation
 Marking for fluid connections must always be complied with and be kept in legible condition at all times.
2.2 Personnel Qualification and Training

All personnel involved in the operation, maintenance, inspection and installation of the machine must be fully qualified to carry
out the work involved.
Personnel responsibilities, competence and supervision must be clearly defined by the operator. If the personnel in question
are not already in possession of the requisite know-how, appropriate training and instruction must be provided. If required, the
operator may commission the manufacturer / supplier to provide such training. In addition, the operator is responsible for
ensuring that the contents of the operating instructions are fully understood by the responsible personnel.
2.3 Non-compliance with Safety Instructions

Non-compliance with safety instructions can jeopardize the safety of personnel, the environment and the machine itself. Non-
compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:

 Failure of important machine / unit functions
 Failure of prescribed maintenance and servicing practices
 Hazard to persons by electrical, mechanical and chemical effects
 Hazard to the environment due to leakage of hazardous substances.
6
LCC
2.4 Safety Awareness
It is imperative to comply with the safety instructions contained in this manual, the relevant national and local health and safety
regulations and the operator’s own internal work, operation and safety regulations.
2.5 Safety Instructions for Operators

 Any hot or cold components that could pose a hazard must be equipped with a guard by the operator.
 Guards that are fitted to prevent accidental contact with moving parts (e.g. coupling) must not be removed while the
machine is operating.
 Leakages (e.g. at the shaft seal) of hazardous media handled (e.g. explosive, toxic, hot) must be contained so as to avoid
any danger to persons and the environment. Pertinent legal provisions must be adhered to.
 Electrical hazards must be eliminated. (Refer to the relevant safety regulations applicable to different countries and / or
the local energy supply companies.)
 Mixing unsuitable media may cause a chemical reaction resulting in a pressure buildup and potential explosion.
2.6 Safety Instructions for Maintenance, Inspection & Installation

 The operator is responsible for ensuring that all maintenance, inspection and installation work is performed by authorized
and qualified personnel who are thoroughly familiar with the manual.
 Work on the machine must be carried out only during standstill. The shutdown procedure described in the manual for
taking the machine out of service must be adhered to without fail.
 Pumps or pump units handling media injurious to health must be decontaminated.
 Immediately following completion of the work, all safety / protective devices must be re-installed and / or re-activated.
 Please observe all instructions set out in the Section 6 “Commissioning” before returning the machine to service.
2.7 Unauthorized Modification and Manufacture of Spare Parts

Modifications or alterations of the machine are only permitted after consultation with the manufacturer. Original spare parts
and accessories authorized by the manufacturer ensure safety. The use of other parts can invalidate any liability of the
manufacturer for damage or warranty.
2.8 Unauthorized Modes of Operation

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

For sectional drawings and bills of material relating to your specific pump and equipment, locate an official copy of
the documentation provided by GIW / KSB. This may be shipped separately from the pump and will include
drawings and bills of material as attachments to this basic manual.
 Dismantling and reassembly must always be carried out in accordance with the rules of sound engineering practice and
the relevant sectional drawings. Any work on the motor, gear reducer, mechanical seal or other non-pump equipment
shall be governed by the specifications and regulations of the respective supplier.
 Before assembly thoroughly clean all dismantled part mating surfaces and check them for signs of wear. Damaged or
worn components are to be replaced by original equipment spare parts. Make sure that the seal faces are clean and the
o-rings and gaskets are properly fitted. It is recommended that new seal elements (o-rings and gaskets) be used
whenever the pump is reassembled. Make sure that new gaskets have the same thickness as the old ones.
 Avoid the use of mounting aids as much as possible. Should a mounting aid be required, use a commercially available
contact adhesive. The adhesive should only be applied at selected points (three to four spots) and in thin layers. Do not
use cyanoacryiate adhesives (quick-setting adhesives). If in certain cases mounting aids or anti-adhesives other than
those described are required, please contact the sealing material manufacturer.
 The operator is responsible for ensuring that all maintenance inspection and installation work is carried out by authorized,
duly qualified staff who are thoroughly familiar with these operating instructions.
 A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the
pump with a minimum of maintenance expenditure.
 Repair and maintenance work to the pump must only be carried out by specially trained personnel, using original
equipment spare parts.
DANGER
Do not apply heat to the impeller hub or nose due to the sealed cavity at the impeller nose.
DANGER OF EXPLOSION!
7
LCC
WARNING
 Proper lifting, rigging and safety practices must be observed at all times. Do not attempt to lift heavy
components by hand as this may result in personal injury and damage to equipment.
 Work on the unit must only be carried out with the electrical connections disconnected and locked
out. Make sure that the pump set cannot be switched on accidentally.
 Pumps handling liquids posing health hazards must be decontaminated. When draining the medium
ensure there is no risk to persons or the environment. All relevant laws must be adhered to.
 Before dismantling or reassembly, secure the pump so as to make sure it cannot be switched on
accidentally. The shut-off elements in the suction and discharge nozzles must be closed. The pump
must have cooled down to ambient temperature, drained, and its pressure must be released.
 Before dismantling or reassembly of vertical cantilever pumps, remove the motor and pull the
assembly out of the sump.
 Upon completion of the work, all safety-related and protective equipment must be properly refitted
and/or reactivated before starting the pump set.
 Always ensure that lifting equipment does not bind the swivel hoist ring. Binding can cause the ring to
fail. When lifting a plate that contains two swivel hoist rings, do not allow the angle between the lines
of tension from the rings to exceed 120°. This could cause the hoist rings to fail.
120°
Do NOT bind lifting equipment Do NOT exceed 120° between lines of tension
8
LCC
3 Transport and Storage
3.1 Transport & Handling Safety
WARNING
 Proper rigging, lifting and safety practices must be observed at all times.
 If the pump / unit slips out of the suspension arrangement, it may cause personal injury and damage
to property.
 Follow proper lifting practice and safety rules at all times, including:
 Verification of the lift weight and load rating of the lift equipment.
 Suitability and stability of the attachment points.
 Be aware of the location of the center of gravity, which is usually NOT located at the physical center of the unit. In general,
the following guidelines will apply, although common sense and testing of the lift before movement should be used to
verify:
 Bare shaft pump (without motor): Near the shaft seal area.
 Pump with overhead mounted motor: Between the pump and motor, slightly behind (towards the drive end) of the
shaft seal.
 Vertical cantilever pump: between the pump and bearing assembly, but closer to the bearing assembly.
 Space the lifting points evenly about the center of gravity and as far apart as practical. This will result in the most stable
lift. Note that certain lift points on the pedestal or bearing housing may be intended for use in handling the pedestal or
bearing house alone and are not necessarily optimum balance points for the entire pump unit.
 See Section 3.3 or any addendums for suggested lifting methods. Actual safe lifting method will vary with pump
configuration and type of lifting equipment.
 Ensure secure attachments and test the lifting method for stability before moving pump.
 For horizontal pumps, ensure that the unit remains in the horizontal position during lifting and cannot slip out of the
suspension arrangement.
 Ensure that the pump is firmly strapped down during shipment. Pump should be protected from direct contact with the
elements. Motors and gear reducers may require immediate cover (consult manufacturer). After arrival on site, consult
GIW Pump Storage recommendations for further storage instructions.
 In corrosive environments be sure to remove all lifting devices from the pump and store in a non-corrosive environment
until needed.
 DO NOT: Use eyebolt or shackle locations on the bearing assembly, motor or pump plates. These are intended for lifting
those items alone and must not be used when lifting the entire pump.
 DO NOT: Place excessive side loads on cast lifting eyes. The side loading angle on any lifting eye should not exceed 30
degrees.
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LCC
3.2 Storage Requirements
3.2.1 Storage of New Pumps – Pumps under Warranty
Consult your sales contract documents and/or your GIW representative for detailed instructions. Note that failure to follow
proper storage procedures will void your warranty.
3.2.2 Pump Storage
CAUTION
 In freezing environments, water must be prevented from collecting in the pump casing.
 Pumps with elastomer linings should be stored in a cool dark location free from electrical equipment
such as motors, or any other ozone generating devices. Exposure to direct sunlight or temperatures
in excess of 50°C (120°F) must be avoided.
 If the pump is fitted with a mechanical seal, motor, sheave, bushing, coupling, gear reducer, or other
auxilarily equipment be sure to consult the manufacturer’s maintenance manual for any additional
storage instructions.
 Auxiliary systems should be regularly tested according to manufacturer’s recommendations.
Storage Upon Receipt and up to 3 Months

 Pump should stored indoors and out of the weather until ready for installation.
 In construction environments where indoor storage is not available, store the pump on blocks or pallets, build a frame
around it and cover with tarpaulin.
o Frame must be able to withstand snow and wind, anchored and built in a manner to last the entire time
pump is in storage. Shelter must be continuously maintained in a stable and leak free condition.
o Ensure the tarpaulin does not touch the pump, since this can lead to condensation. Leave the bottom open
for ventilation. Minimum Tarp requirements:
- 18oz Vinyl - 20mil thick - Water proof - UV resistant
Storage Exceeding 3 Months

 If pump is exposed to the weather at any time the frame requirements still stand.
 The Wet End pump parts should be drained and isolated from reaction vessel gasses.
 Check the rust inhibitor coatings on bare metal surfaces and renew exposed areas.
 Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
 Check that the threaded holes are protected with grease and plugged.
 Oil lubricated bearing assemblies with GIW Blue Oil (requires shaft rotation):
o GIW Blue Oil supplied with the pump should be added to the bearing housing until the level is halfway of the
Oil Sight Glass (642).
o Pump shaft should be manually rotated approximately 5 turns each month to keep the bearings coated.
o Vertical pumps should have the Lubrication Oil System running while the shaft is rotated 5 turns each
month.
o The oil should be replaced if shutdown duration exceeds 12 months.
 Oil lubricated bearing assemblies with GIW Storage Oil (alternative to shaft rotation):
o GIW Storage Oil should be added to the bearing housing until the level is halfway of the Oil Sight Glass
(642) and rotate the shaft several times. No further shaft rotation is needed
o The bearing assembly must remain sealed in the factory assembled condition. The oil fill plug must be
securely replaced and no breather or other vent added to the bearing housing.
o Vertical pumps should be stored horizontally and filled with Storage Oil to the center of the sight glass or 1
inch (25mm) below the largest diameter Inpro/Seal bearing isolator, whichever is lower.
o The storage oil should be replaced if shutdown duration exceeds 12 months.
 Grease lubricated bearing assemblies do not require monthly rotation.
 If the pump is fitted with a mechanical seal, precautions may need to be taken before rotating the shaft. Refer to the
seal manufacturer’s maintenance manual for instructions.
 Pumps with InPro/Seal® bearing isolators must be coated externally with white grease or petroleum jelly to seal the
gap between the rotor and stator. Units equipped with a vent kit must have the vents either removed and plugged, or
blocked to prevent air exchange.
 Vertical pumps should be stored horizontally, and the blocking on the shaft should be left in place until the pump is
ready to be installed.
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LCC
Storage Exceeding 12 Months (Long Term Storage)
The following information on long term storage pertains to GIW pump assemblies only and does NOT cover any auxiliary
equipment such as motors, gearboxes, lube oil systems, etc... Long term storage for auxiliary equipment must be included in
the contract and negotiated with sub-vendors at time of order.
At 12 months storage and again at 24 months of storage, the following additional actions should be taken:
 Check the rust inhibitor coatings on bare metal surfaces and renew exposed areas.
 Replace the GIW Oil and/or Storage Oil, if applicable.
Installed Spares (Idle Pumps)

 After being idle to 1 or more months, shafts must be rotated through five (5) or more revolutions, either manually or
by a short duration start-up. If regularly exposed to moisture (weather or process related), monthly oil analysis is
recommended since idle bearing assemblies are subject to breathing and internal condensation due to ambient
temperature fluctuations.
 After being idle for 3 or more months, oil change or oil analysis is recommended for all pumps to ensure against
condensation.
 After being idle for 12 months or more, the oil should be replaced.
3.2.3 Pump Parts Storage
CAUTION
For proper storage ensure:

 All machined surfaces must be coated with rust protector
 Grease and plug all drilled and threaded holes
 Check monthly for paint breakdown on casting
 Check monthly for visible sign of rust on machine surface
 Check monthly forgeign matter buildup in drilled/threaded holes
 Remove rust with wire brush and recoat machined surfaces with a rust inhibitor as needed
 Remove rust with wire brush and repaint casting surfaces as needed
All pump parts must be stored indoors. The only exception is for large castings such as pedestals, pump
casings, impellers, etc… See chart below for details.
Pump Part Storage Requirements
Pedestal Plate
Casing Impeller Outdoor storage with monthly inspection permitted for these parts only
Casing Half Sub-base Lay sub-bases flat and do not stack
Liner
Check expiration date (shelf life is 5 years)

Keep dry, out of direct sunlight or other UV sources and away from heat.
Store in the box with part being covered with the black plastic, low density, polyethylene
Rubber Urethane bags (4 mil minimum thickness) and re-seal the boxes.
Elastomers Neoprene Periodically inspect for the presence of a soft chalky layer, easily rubbed off, which would
indicate deterioration
Darkening or discoloration of elastomer parts over time is a natural occurrence and does
not by itself indicate any loss of properties.
Shaft Sleeve Lantern Ring

Coat complete part with rust protector
Wear Plate
Shaft Coat complete part with rust protector and wrap with 6mil VCI plastic
Check expiration date (shelf life is typically 5 years)

O-Ring Gasket
Keep dry, out of direct sunlight and away from heat
Check expiration date (shelf life is typically 1 year)

Bearings InPro Seals Refer to Manufacturer’s Storage guidelines
Stat-o-Seals Keep in unopened box provided by the vendor
Keep dry, out of direct sunlight and lay flat
Motor Sheave
Gear Reducer Bushing  Refer to manufacturer’s storage guidelines
Coupling etc…
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LCC
3.2.4 Removal from Storage
 Remove rust from machined surfaces using a wire brush.
 Remove rust inhibitor from all machined surfaces prior to installation/assembly.
 It is recommended that the bearing assembly be drained before shipment and refilled after relocation or installation.
 If GIW Blue Oil with rotation was used and the pump is stored for less than 12 months, the same oil may be used for
initial commissioning and break in. Otherwise, it is recommended that the oil be replaced prior to commissioning to
remove any moisture.
 If GIW Storage Oil was used, it should be drained and replaced with GIW Blue Oil before startup.
 For grease lubricated units, a fresh application of grease in the amount recommended by the maintenance manual for
a normal lubrication interval should be applied.
 Stuffing Box should be checked before start up and replaced if necessary. Packing may have dried out and need
multiple readjustments during the start-up process.
 If the pump is fitted with a mechanical seal, motor, sheave, bushing, coupling, gear reducer, or other auxilarily
equipment be sure to consult the manufacturer’s maintenance manual for any additional storage removal and
commissioning instructions.
 Consult the Section 6 “Commissioning” before putting the pump into service.
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LCC
3.3 Recommended Lifting
WARNING
Actual safe lifting method will vary with pump configuration and type of lifting equipment
Transport of the pump
WARNING: Very top heavy
Transport of the complete pump unit
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LCC
4. Description
4.1 Technical Specification
The LCC pump range is an international product and has been designed, in most respects, to the METRIC system of units
using metric components. All fasteners are metric and will require metric tooling. All seals are metric including oil seals, O-
rings and stuffing box packing.
Two important exceptions:
1) The suction and discharge flange bolting patterns are to the American (ANSI) standard, however, flange adapting spools
are available.
2) The drive end bearing is an inch based taper roller bearing.
Centrifugal pump for handling coarse or fine particles from solids-laden waste water to aggressive slurries of an abrasive or
corrosive nature. Applications include process pumping and tailings disposal for mining, dredging and other industrial
operations.
4.2 Designation
LCC-M 300-710.5M C M1 Options
Pump Type O Open Shroud Impeller
Hydraulic Type AF Oil Lubricated Face to Face
Discharge Nozzle (mm) AB Oil Lubricated Back to Back
Nominal Impeller Diameter (mm) UF Underwater Oil Lubricated Face to Face
Mechanical Size UB Underwater Oil Lubricated Back to Back
Seal Type GF Grease Lubricated Face to Face
Options GB Grease Lubricated Back to Back
Material Code T Turn Down Impeller
C Elastomer Impeller
Hydraulic Type
M Metal Material Code
R Rubber M1 Metal
H Heavy Construction MC2 Metal / Chemical
R1 Rubber
Mechanical (Frame) Size
1 2 3 4 5 Nominal Flange and Impeller Diameters in mm (inches)
35 mm 50 mm 70 mm 100 mm 125 mm Designation Discharge Suction Impeller
LCC 50 - 230 50 ( 2”) 80 ( 3” ) 225 ( 8.86” )
Seal Type LCC 80 - 300 80 ( 3” ) 100 ( 4” ) 310 ( 12.22”)
K KE LCC 100 - 400 100 ( 4” ) 150 ( 6” ) 395 ( 15.55”)
B Throat Bushing LCC 150 - 500 150 ( 6” ) 200 ( 8” ) 500 ( 19.69” )
M Mechanical Seal LCC 200 - 610 200 ( 8” ) 250 ( 10”) 610 ( 24” )
E Expeller LCC 250 - 660 250 (10”) 300 ( 12”) 660 ( 26” )
LCC 300 - 710 300 ( 12”) 350 ( 14”) 710 ( 27.95”)
For additional information concerning the LCC family of pumps, contact your GIW / KSB representative.
4.3 Design Details

Horizontal, end suction, modified volute casing pump with three-vane impeller for large solids passage. Available in
interchangeable elastomer, metal and extra-heavy designs.
4.4 Noise Characteristics
WARNING
The addition of coarse solids, froth or cavitating conditions can significantly increase the noise levels in both
the pump and piping. If accurate noise levels are required for these conditions, field-testing will be required.
If running within the normal limits of operation and with clear water, the sound pressure level for the pump alone (with gear box
and motor noises shielded) does not exceed 85 dB(A) at one meter.
Sound pressure levels from motor and gear reducer must be added to the above in accordance with standard acoustic
formulas, taking into account the distance between units. For belt driven units, add an additional 2 dB.
4.5 Accessories
Couplings, pulleys, belts, motor mounts and/or base plates may be provided. Refer to the bill-of-materials, data sheets and/or
drawings for further information.
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LCC
4.6 Dimensions and Weights
Dimensions and weights are listed on the pump installation plan.
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LCC
4.7 Forces and Moments at Nozzles
Below are the allowable combined branch loads applicable for all GIW slurry pumps. Fzd
Methods based on ANSI/HI 12.1-12.6-2011 Slurry Pump Standard. Loads generally
exceed HI/ANSI 9.6.2-2008 table 9.6.2.1.4a and API 610-2004, Table 4. Higher Mzd
Mxd
allowable loads may be possible depending on individual pump configuration and
operating conditions. Contact your GIW Application Engineer for more information. Fxd Myd
NOTE: Discharge branch coordinate system always moves with the branch angle. Fzs Fyd
(Fz is always along the direction of flow). Mzs
Mxs
Fxs Mys
Fys
Allowable Forces Allowable Moments

Flange Size FX FY FZ MX MY MZ
inch mm lbs N lbs N lbs N ft-lbs N-m ft-lbs N-m ft-lbs N-m
2 50 1600 7110 1280 5690 3250 14450 2640 3570 2640 3570 4000 5420
3 75 1760 7840 1410 6270 3410 15180 2900 3930 2900 3930 4390 5960
4 100 1930 8590 1550 6890 3580 15930 3160 4290 3160 4290 4790 6500
6 150 2270 10110 1820 8090 3920 17450 3680 4990 3680 4990 5580 7570
8 200 2630 11700 2100 9340 4280 19040 4200 5690 4200 5690 6360 8620
10 250 3010 13390 2410 10710 4660 20730 4700 6380 4700 6380 7130 9670
DISCHARGE PIPE
12 300 3420 15230 2740 12180 5070 22560 5210 7070 5210 7070 7900 10710
14 350 3890 17300 3110 13830 5540 24640 5710 7740 5710 7740 8650 11730
16 400 4440 19760 3550 15790 6090 27100 6200 8410 6200 8410 9400 12750
18 450 5110 22750 4090 18190 6760 30090 6690 9070 6690 9070 10140 13750
20 500 5900 26240 4720 20990 7550 33580 7170 9730 7170 9730 10870 14740
22 550 6680 29730 5350 23790 8330 37070 7650 10380 7650 10380 11600 15720
24 600 7350 32720 5890 26190 9000 40060 8120 11020 8120 11020 12310 16700
26 650 7900 35170 6330 28150 9550 42510 8590 11650 8590 11650 13020 17660
30 750 8780 39090 7030 31260 10430 46430 9510 12900 9510 12900 14410 19540
36 900 9860 43890 7890 35090 11510 51230 10850 14710 10850 14710 16440 22290
38 950 10150 45170 8120 36150 11820 52580 11280 15300 11280 15300 17100 23190
3 75 3410 15180 1760 7840 1410 6270 4390 5960 2900 3930 2900 3930
4 100 3580 15930 1930 8590 1550 6890 4790 6500 3160 4290 3160 4290
6 150 3920 17450 2270 10110 1820 8090 5580 7570 3680 4990 3680 4990
8 200 4280 19040 2630 11700 2100 9340 6360 8620 4200 5690 4200 5690
10 250 4660 20730 3010 13390 2410 10710 7130 9670 4700 6380 4700 6380
12 300 5070 22560 3420 15230 2740 12180 7900 10710 5210 7070 5210 7070
14 350 5540 24640 3890 17300 3110 13830 8650 11730 5710 7740 5710 7740
SUCTION PIPE
16 400 6090 27100 4440 19760 3550 15790 9400 12750 6200 8410 6200 8410
18 450 6860 30090 5110 22750 4090 18190 10140 13750 6690 9070 6690 9070
20 500 7550 33580 5900 26240 4720 20990 10870 14740 7170 9730 7170 9730
22 550 8330 37070 6680 29730 5350 23790 11600 15720 7650 10380 7650 10380
24 600 9000 40060 7350 32720 5890 26190 12310 16700 8120 11020 8120 11020
26 650 9550 42510 7900 35170 6330 28150 13020 17660 8590 11650 8590 11650
28 700 10020 44590 8370 37250 6700 29800 13720 18600 9050 12280 9050 12280
30 750 10430 46430 8780 39090 7030 31260 14410 19540 9510 12900 9510 12900
34 850 11170 49710 9520 42370 7620 33890 15770 21390 10410 14110 10410 14110
36 900 11510 51230 9860 43890 7890 35090 16440 22290 10850 14710 10850 14710
38 950 11820 52580 10150 45170 8120 36150 17100 23190 11280 15300 11280 15300
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LCC
5 Installation at Site
5.1 Safety Regulations
WARNING
Electrical equipment operated in hazardous locations must comply with the applicable explosion protection
regulations. This is indicated on the motor rating plate. If the equipment is installed in hazardous locations, the
applicable local explosion protection regulations and the regulations of the test certificate supplied with the
equipment and issued by the responsible approval authorities must be observed and complied with. The test
certificate must be kept close to the location of operation for easy access.
5.2 Foundation
WARNING
Appropriate personal protective equipment should be worn when handling concrete and grouting materials.
All structural work required must have been prepared in accordance with the dimensions stated in the dimension table /
installation plan.
The concrete foundation shall have sufficient strength for the pump and be completely cured before installation. The mounting
surface must be flat and level. Anchor bolts must be located according to the installation plan. This can be done when the
concrete is poured, or by drilling holes in existing foundations and grouting the bolts in place.
5.3 Installing the Baseplate and Pump
WARNING
Do not install the baseplate and pump on unpaved or unsupported foundations. Injury can result from vibration
or shifting equipment.
After placing the baseplate on the foundation, it must be leveled by shimming. Shims should be fitted between the baseplate
and the foundation itself; they should always be inserted to the left and right of the foundation bolts and in close proximity to
these bolts. For a bolt-to-bolt clearance of more than 800mm (30 in.), additional shims should be inserted halfway between the
adjoining holes. All shims must lie perfectly flush.
Insert the foundation bolts and set them into the foundation using concrete. When the mortar has set, tighten the foundation
bolts evenly and firmly and grout the baseplate using low shrinkage grout.
Shim Shim Shim

 800
Foundation bolts
5.3.1 Aligning the Pump / Drive Train for Horizontal Pump Application
WARNING
 Use of the mounting bolts to close gaps between motor feet and the mounting plate (in place of
shimming) is not recommended and may result in twisting of the motor frame, “soft foot” mounting
and excessive vibration.
 Care must be taken when removing drive components to avoid personal injury or damage to the
equipment. Avoid contact with hot surfaces such as couplings, which may heat up during normal
operation and cause injury.
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LCC
CAUTION
 All components must be level during system operation unless special provisions for bearing
lubrication and oil sealing have been made. After attaching the unit to the foundation and connecting
the piping, the pump and drive train must be thoroughly checked and, if necessary, realigned.
 Improper alignment of the unit can cause damage to both the coupling and the unit itself.
 Proper alignment must be taken into consideration when using an overhead motor mount accessory. Motor feet must be
firmly supported at each mounting bolt location before the bolts are tightened. Shims should be used to fill any gaps and
ensure solid mounting and vibration prevention.
 For optimum performance, the pump should be mounted directly to the baseplate without shims. The rest of the drive train
is then aligned to the pump. For this reason, GIW baseplate designs generally allow space for shimming under the gear
reducer and motor, but not under the pump itself. The only exception occurs in cases where regular removal and
replacement of the entire pump is stipulated during the equipment design stage. In these cases, special instructions for
alignment and shimming of the pump may be given on the pump assembly and/or general arrangement drawings.
 Coupling check and realignment must be done even if pump and motor are supplied completely assembled and aligned
on a common base plate. The correct distance between the coupling halves as specified in the installation plan must be
observed.
 The pump set is correctly aligned if a straightedge placed axially on both coupling halves is the same distance from each
shaft at all points around the circumference. In addition, the distance between the two coupling halves must remain the
same all around the circumference. Use a feeler gauge, a wedge gauge or a dial micrometer to verify.
 The radial and axial deviation (tolerance) between the two coupling halves should not exceed 0.1 mm (0.004 inch).
 For V-belt installations, the pulleys are correctly aligned if a straightedge placed vertically shows a deviation of no more
than 1.0 mm (0.04 in.). Both pulleys must be parallel.
Straight Edge Angular Misalignment Offset Misalignment
RPM Excellent Acceptable Excellent Acceptable

μm μm
900 1.0 1.5 100μm 200μm
mm mm
μm μm
1200 0.7 1.0 75μm 150μm
mm mm
μm μm
1800 0.5 0.7 50μm 100μm
mm mm
μm μm align max. 1mm
Gauge 3600 0.3 0.5 25μm 50μm
mm mm
Coupling Alignment Typical industry standard for coupling alignment V-belt Pulley Alignment
5.3.2 Place of Installation
WARNING
The volute casing and shaft seal take on roughly the same temperature as the medium handled.
The shaft seal seal, bearing assembly and bearing housing must not be insulated.
Take the necessary precautions to avoid burns to personnel and adjacent equipment.
5.4 Connecting the Piping
WARNING
Danger of life when toxic or hot media are handled.
CAUTION
Never use the pump itself as an anchorage point for the piping.
Permissible forces and moments must not be exceeded (see to section 4.7).
Refer to your drawing for spool piece recommendation to ease maintenance.
 Thermal expansions of the pipelines must be compensated by appropriate measures so as not to impose any extra loads
on the pump exceeding the permissible pipeline forces and moments.
 An excessive, impermissible increase in the pipeline forces may cause leaks on the pump where the medium handled can
escape into the atmosphere.
 The flange covers on the pump suction and discharge nozzles must be removed prior to installation in the piping.
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LCC
5.4.1 Auxiliary Connections
CAUTION
These connections are required for proper functioning of the pump and are therefore of vital importance!
The dimensions and locations of the auxiliary connections (cooling, heating, sealing liquid, flushing liquid, etc.)
are indicated on the installation plan or piping layout.
5.5 Safety Guards
WARNING
In compliance with the accident prevention regulations the pump must not be operated without coupling and
drive guards. If the customer specifically requests not to include guards in our delivery, then the operator must
supply them.
5.6 Oil Temperature Monitoring (RTD)

RTD (Resistance Temperature Detector) units are usually shipped separately along with the fittings needed to install them.
Care should be taken during assembly. Any fittings should be assembled and installed in the bearing housing before installing
the RTD units. Use an oil compatible sealer on the threads during installation. Be sure to tighten fittings so that any oil drain
plug is facing in the down position. After all fittings are installed, install the RTD unit. Take care not to drop or damage the RTD
unit during installation. After the entire assembly is complete, the bearing assembly can be put back into service. The
assembly should be inspected for leaks.
5.7 Final Check

Verify the alignment as described in Section 5.3.1. It must be easy to rotate the shaft by hand at the coupling.
5.8 Connection to Power Supply
WARNING
 A trained electrician must make the connection to the power supply. Check available main voltage
against the data on the motor rating plate and select the appropriate start-up method. The use of a
motor protection device is strongly recommended.
 An emergency shut off switch should be installed to prevent damage to the personnel and
environment in the event of hazardous pump operation.
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LCC
6 Commissioning, Startup and Shutdown
CAUTION
Compliance with the following requirements is of paramount importance. Damage resulting from non-
compliance shall not be covered by the scope of warranty. This manual applies to single stage pumps.
Procedures for multistage pumps should be obtained from the GIW/KSB sales office.
This manual applies to single stage pumps. Procedures for multistage pumps should be obtained from GIW/KSB sales office.
6.1 Commissioning / Return to Service
WARNING
Before starting up the pump make sure that the following requirements are checked and fulfilled:
1. If the pump has been in long term storage (more than 3 months), proper storage procedures were
followed, including instructions for removing the pumps from storage (see contract documents and/or
contact your GIW representative). Failure to follow proper storage procedures will void your warranty.
See Section 3.2 “Storage Requirements”.
2. The impeller nose clearance has been properly set.
See Section 10.4 “Setting Impeller Nose Gap” for details.
3. Pump drive train final alignment is complete.
See Section 5.3.1 “Alignment” for details.
4. Final torquing of all bolts has been completed.
See Section 11.1 “General Torque” for details.
5. All electrical and power supply connections are in order, including fuses and overload protection devices.
See Section 5.1 “Safety Regulations” for details.
6. All required auxiliary connections, such as shaft seal water, oil coolers, etc. are made, tested and ready to
function.
See Section 5.4.1 “Auxillary Connection” for details.
7. All safety guards and equipment are in place.
See Section 5.5 “Safety Guards” for details.
8. Any required instrumentation has been properly installed.
See Section 5.6 “Oil Temperature Monitoring” for details on RTD installation.
9. Bearing assembly lubrication is completed.
See Section 6.1.1 “Bearing Lubrication” for details.
10. Shaft seal is ready for operation
See Section 6.1.2 “Shaft Seal Commissioning” for details.
11. Drive train direction of rotation at the pump is correct.
See Section 6.1.3 “Checking the Direction of Rotation” for details.
12. The pump set is primed.
See Section 6.2.1. “Priming the Pump”
13. The desired operating conditions do not exceed those allowed by the pump.
See Section 6.4 “Operating Limits” for details.
6.1.1 Bearing Lubrication

Grease Lubricated Bearings
 Grease lubricated bearings are packed with grease at the factory. They should be re-lubricated after the initial 50 hours of
operation, and at regular intervals thereafter.
 If shaft speeds exceed those in the table below, the bearing housing temperature should be monitored during
commissioning and additional grease added if it exceeds 100 °C (210 °F), or if bearings are noisy . In some cases where
external cooling of the housing is poor, it may be necessary to stop and allow the bearings to cool several times during
this break-in period.
 The bearing cavities should be fully packed with grease.
 After adding grease, some excess may be expelled from the labyrinth oil seals. This is normal and will stop once the
excess grease has been purged.
 Use high-quality lithium-soap grease, free of resin and acid, not liable to crumble and with good rust-preventive
characteristics.
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LCC
Approximate Grease Capacity
Bearing *Shaft Speed Spherical Taper
Assembly RPM Roller Bearing Roller Bearing
mL (oz) mL (oz)
35mm 2300 15 (0.5) 20 (0.7)
50mm 1800 20 (0.7) 40 (1.4)
70mm 1400 30 (1.0) 90 (3.0)
100mm 1000 90 (3.0) 190 (6.4)
125mm 750 140 (4.7) 280 (9.5)
*Monitor commission temperature if exceeded
Oil-lubricated bearings
CAUTION
Pump bearing units are shipped empty of oil. Before starting the pump, fill them to the center of the oil level
sight gauge using the GIW Blue 150 synthetic bearing oil supplied with the unit. For vertical pumps, fill the oil
reservoir.
If locally obtained oil is desired, use an equivalent synthetic or a high quality ISO220 or 320 mineral oil suitable for use with
heavy industrial equipment, anti-friction bearings and oil circulating systems. Such oil typically has high temperature stability,
resistance to oxidation and foaming, and inhibits rust, corrosion, and the formation of deposits. Oils with EP additives are not
generally recommended. Detailed bearing oil specifications and GIW Blue replacement oil are available from GIW.
Oil operating temperatures for GIW bearing assemblies will depend on pump size, speed and ambient conditions. Under
typical conditions, they will run from 50 °C – 85 °C (125 °F – 185°F). For oil temperatures above 85 °C (185 °F) or for severe
load conditions, a high quality synthetic lubricant (such as GIW Blue) should be used. At higher speeds, or in hotter ambient
conditions, temperatures can rise to 100 °C (210 °F). Slightly higher temperatures may be seen for a brief period during the
breaking in of new bearings. The unit should be shut down immediately if temperatures rise to 120 °C (250 °F).
Do not overfill the bearing assembly. The capacities listed are

approximate. When filling the bearing housing, the oil level
must be at the centerline of the oil level sight glass when the
shaft is not turning. This is the ”cold level” and will change as Approximate Oil Capacity
Bearing Assembly
the pump runs and the oil becomes suspended in the bearings. liter quart
35 mm 0.75 0.75
The oil should be initially drained after 50 to 100 hours 50 mm 1.00 1.00
operation. Before refilling, the bearings should be flushed by 70 mm 1.75 2.00
filling the bearing housing with a lightweight oil, turning the 100 mm 3.00 3.25
pump shaft several rotations, and then draining. This should be
125 mm 6.00 6.50
repeated until the flushed oil appears clean.
Bearing assemblies for use underwater should be completely

filled with oil and slightly pressurized by an oil recirculation and Water Temperature ISO Viscosity Grade
filtering system. As a result, their capacities will be several 0 °C – 20 °C (32 °F – 70 °F) 100
times greater than shown above and a thinner oil will be 20 °C – 30 °C (70 °F – 85 °F) 150
required. Depending upon the water temperature at the > 30 °C (> 85 °F) 200
location at which the pumps are operating, the ISO viscosity GIW Blue oil may be used for all the above temperatures
grade should be altered as follows for mineral oil-based
lubricants. See Section 6.5 for more details on Underwater
Pump Operation.
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6.1.2 Shaft Seal Commissioning
Mechanical Seals
CAUTION
Mechanical seals require safety checks prior to start-up such as removing seal assembly fixtures, checking
axial alignment, checking torques etc. Refer to the mechanical seal operating manual for all required safety
checks.
Mechanical seals are precision devices which require special care for their proper operation. The instruction manual for the
seal should be consulted for special storage, start-up, and maintenance requirements.
If the pump is equipped with a deaeration chamber (HVF), the mechanical seal must be of the double faced type with barrier
fluid. This will prevent dry running and seal face destruction.
Stuffing Box Commissioning

Prior to commissioning, the gland packing supplied with the pump must be adjusted. Preformed packing rings sets from GIW /
KSB are recommended. For alternate brands, refer to packing manufacturer’s instructions regarding installation and use.
For gland flush supply, use suitable non-aggressive clean water not liable to form deposits and not containing suspended
solids. Hardness should average 5 with a pH>8. It should be conditioned and neutral with regards to mechanical corrosion.
An Inlet Temperature of 10 °C – 30 °C (50 °F – 85 °F) should produce a maximum Outlet Temperature 45 °C (115 °F) when
the gland is properly adjusted.
6.1.3 Checking the Direction of Rotation
CAUTION
If motive power is applied to the pump, and it is run in the wrong direction of rotation, even momentarily, the
impeller may unscrew causing extensive damage to the entire unit. This is especially important during initial
start up as the impeller may not be fully torqued onto the pump shaft.
The impeller must rotate in the correct direction of rotation. This must be verified by briefly running the motor with the coupling
or belt drive disconnected. If the motor runs in the wrong direction of rotation, have it corrected and verify direction of rotation
before reconnecting coupling or belts.
If a Variable Frequency Drive (VFD) or other controller is used, it is recommended to permanently disable REVERSE and
BRAKE function during controller set up.
6.1.4 Cleaning the Plant Piping
WARNING
Cleaning operations for flushing and pickling service must be matched to the casing and seal materials used.
Any chemicals or high temperatures used must be compatible with all pump parts.
6.1.5 Suction Strainer

If a suction strainer has been fitted to protect the pumps against dirt and/or to retain contamination from the plant, the
strainer’s contamination level must be monitored by measuring the differential pressure so as to ensure adequate inlet
pressure for the pump.
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6.2 Startup
WARNING
 Start-up, shutdown, filling and draining procedures must be designed to prevent any possibility of
negative torque being experienced on the pump shaft. Negative torque can cause the impeller to
unscrew, leading to severe damage throughout the rotating assembly and drive train. In particular,
the following practices must be avoided:
1. Any flow through the idle pump, in any direction, in excess of 5% of the normal operating flow
rate before the impeller has been tightened by running under normal loads. This includes flow
due to filling or draining of the system and/or flow caused by the equalization of different levels
between the sump and discharge line after the opening of any valves in the piping.
2. Any attempt to restrict the flow after shutdown, by either manual or automatic systems, until the
pump comes to a complete standstill.
3. Any braking or re-energizing of the drive train after shutdown, until the system has reached a
complete static condition.
 Prolonged operation at zero or low flow, typically due to closed valve or unintended pipeline
blockage, is not permitted. Danger of steam generation and explosion.
 Start-up and shutdown procedures must be designed to prevent any possibility of water hammer.
Water hammer can place excessive loads on the piping, resulting in damage to the pump flanges.
The pressure waves generated by water hammer can also cause damage to the pressure containing
components of the pump, the mechanical end and/or the mechanical seal.
CAUTION
During the initial commissioning, once the pump and bearing assembly stabilize at normal operating
temperature, or in the event of system leaks, stop the unit and re-tighten all bolts. Check the coupling
alignment and re-align if necessary.
 Before starting the pump verify that the shut-off element in the suction line is fully open.
 The pump may be started up against a closed discharge shut-off element. Once the pump has reached full rotational
speed, open the discharge valve slowly and adjusted to the duty point.
 When starting up against an open discharge-side shut-off element, take the resulting increase in input power
requirements into account.
6.2.1 Priming the Pump
WARNING
The pump should never be run dry and air intake must be minimized using proper sump design. May result in
excess temperatures and escape of medium into the atmosphere due to shaft seal failure. Additionally air
intake must be minimized using proper sump design.
Before start-up, the pump, suction line and (if applicable) the tank must be vented and primed with the liquid to be pumped.
Any valve in the suction line must be fully open. Open all auxiliary connections (flushing, sealing, cooling liquid, etc.) and
check the through flow.
6.3 Shutdown
CAUTION
 Pipe system design and pump operation should prevent damage to the pump during a scheduled or
emergency shutdown.
 In the event of shutdown where a significant static discharge head exists in the system, the impeller
can begin to run back-wards as the flow reverses in the pipeline. This creates a positive torque on the
shaft so the impeller connection will not unscrew. Until the flow stops, do not close any main line
valves. A change in fluid velocity can create a negative torque on the impeller and unscrew it from the
shaft. This can damage wet end pump parts as well as bearings, seals and other components.
 Under no circumstances should the pipe system be equipped with a check valve or other device that can rapidly
decelerate the flow rate.
 Switch off the drive, making sure that the unit runs smoothly down to a complete stop. Variable Frequency Drive (VFD)
and other controllers must not use any braking function to slow the pump. Diesel power trains should disengage the clutch
and allow the pump to coast to a stop.
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 Close any auxiliary connections. Pressurized bearing lubrication systems must remain running until all rotation has
stopped. If the any part of the system uses a cooling liquid supply, turn that off only after the pump has cooled down.
Where liquid filled shaft seals are used, consult seal maintenance manual for specific shutdown procedures.
 Where temperatures may drop below freezing, the pump and system must be drained or otherwise protected against
freezing.
 If the pump is equiped with an deaeration chamber (HVF) the following steps may be taken to reduce the amount of fluid
in the vent pipe and hose:
1. Reduce suction pressure to 10kPa / 1.5 psig by lowering the sump level
2. Close the vent valve to stop slurry from re-entering the vent hose
6.3.1 Measures to be taken for Prolonged Shutdown

1 The pump remains installed - operation check run
In order to make sure that the pump is always ready for instant start-up and to prevent the formation of deposits within the
pump and the pump intake area, start up the pump set regularly once a month for a short time (approx. 5 minutes) during
prolonged shutdown periods. Prior to an operation check run ensure that there is sufficient liquid available for operating the
pump.
2 The pump is dismantled and stored

Before putting the pump into storage carry out all checks specified in Section 3.2 “Storage Requirements”. It is advisable to
close the nozzles (for ex. with plastic caps or similar).
6.4 Operating Limits
WARNING
The pump / unit application limits (speed, minimum and maximum flow, head, fluid density, particle size,
temperature, pH, chloride content, etc…) as stated on the data sheet must be observed. Failure to do so may
result in power overload, excessive vibration, overheating, and/or excessive corrosion or wear. If a data sheet
is not available, contact your GIW / KSB representative.
CAUTION
Any make up water or outside water supply for the system must be installed so that the GIW pump will never
be exposed to a pressure in excess of its maximum allowable operating pressure.
6.4.1 Temperature Limits
CAUTION
Do not operate the pump at temperatures exceeding those specified on the data sheet or the nameplate
unless the written permission of the manufacturer has been obtained.
 Damage resulting from disregarding this warning will not be covered by the manufacturer’s warranty.
 Bearing temperatures must be observed. Excessive bearing temperature could indicate misalignment or other technical
problem.
6.4.2 Switching Frequency

To prevent high temperature increases in the motor and excessive loads on the pump, coupling, motor, seals and bearings,
the switching frequency should not exceed the following number of start-ups per hour.
Motor rating Max switchings per hour

< 12 kW (< 16 hp) 25
12 kW – 100 kW (16 hp – 135 hp) 20
> 100 kW (> 135 hp) 10
6.4.3 Density of the Medium Handled

The power input of the pump will increase in proportion to the density of the medium handled. To avoid overloading of the
motor, pump and coupling, the density of the medium must comply with the data specified on the purchase order.
6.5 Underwater Pump Operation

The Underwater Cartridge Bearing Assembly (UCBA) uses Duo-Cone seals in the end cover. Sealing is accomplished with
two hardened, precision ground faces running against each other. An elastomer toric applies pressure to the faces and allows
the seal rings to accommodate axial and radial run out. The contact pressure and shaft speed will generate heat in the seal
faces that must be removed by the surrounding water as the pump is running. Correct installation and adjustment is extremely
critical to the proper function and life of these seals.
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Due to the angular position of ladder mounted pumps in most dredge operations, the UCBA must be completely filled with oil
to provide lubrication to the rear thrust bearing when the cutter head is lowered. This requires the use of tank mounted above
the deck to detect leaks and accommodate internal pressure changes. A pressurized recirculating system can be used, but the
simplest method is an expansion tank suitable for operation within the marine environment. This must be designed to prevent
dirt, water or other contaminants from entering the oil system while providing a vent to atmosphere.
This tank keeps a positive pressure on the bearing side of the Duo-Cone seals to counteract the water pressure as the pump
is submerged. The tank should be mounted high enough to maintain a pressure of about 7 psi (0.5 bar) above what is created
by the maximum water depth. Note that the specific gravity of oil is only about 85% of water and must be taken into account
when calculating the mounting height of the tank.
The tank should have an oil level indicator to allow the operator to see if the level changes. After the oil temperature stabilizes,
the level should remain constant and any significant change would indicate a leaking seal. This early warning can prevent oil
from leaking into the surrounding water and avoid bearing failure.
Dredge pumps are designed to run with the UCBA and Duo-Cone seals fully submerged. This enables the surrounding water
to dissipate heat generated by the bearings and seal faces. If the pump will be operated above the water line for extended
periods, the bearings can create extra heat in the oil and the seal faces may overheat. Provisions should be made to provide a
supply of cooling water to each Duo-Cone seal and a water spray onto the UCBA itself. If the pump will run continuously above
water, other sealing systems are recommended, or oil circulating and seal cooling systems will be required.
Care should be taken to operate the pump within the speed limitations specified by GIW on the pump drawing for the particular
seal size installed. If a seal is replaced, it must be installed with the correct gap (specified by GIW for each seal size) between
the seal holders, as this distance provides the correct seal face pressure for proper operation.
Failure to operate the seals within the above parameters may result in premature seal failure or oil leakage through the Duo-
Cone seals. Any change in the operating conditions should be discussed with your GIW / KSB representative to establish if the
new conditions are suitable for the equipment.
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7 Maintenance
WARNING
Refer to Section 2.9 “Assembly & Disassembly Safety” prior to working on the pump.
7.1 Supervision of Operation
WARNING
 Operational procedures which may cause system water hammer must be avoided. Sudden and
catastrophic failure of pump casing and plates may result.
 Prolonged operation against a closed shut-off element is not permitted. Danger of steam generation
and explosion!
CAUTION
 Neglect of maintenance procedures and monitoring can result in failure and leakage of the shaft seal,
bearing seals, and wear components.
 The pump should run quietly and free from vibrations at all times. Unusual noise or vibration should
be investigated and corrected immediately.
 If the flexible coupling elements begin to show signs of wear, they should be replaced.
 When running the pump against a closed discharge-side shut-off element for a short period, the permissible pressure and
temperature values must not be exceeded.
 Verify the oil level is correct.
 The gland packing (if the pump is fitted with one) should drip slightly during operation. The gland should only be gently
tightened.
 Any stand-by pumps installed should be switched on and off again as described in Section 6.3.1 “Measures to be taken
for Prolonged Shutdown”.
7.2 Drainage / Disposal
CAUTION
If the pump was used for handling liquids posing health hazards, see to it that there is no risk to persons or the
environment when draining the medium. All relevant laws, local codes, and safety procedures must be
heeded. If required, wear safety clothing and a protective mask.
If the media handled by the pumps leaves residues which might lead to corrosion when coming into contact with atmospheric
humidity, or which might ignite when coming into contact with oxygen, the unit must be flushed thoroughly and neutralized.
The flushing liquid used and any liquid residues in the pump must be properly collected and disposed of without posing any
risk to persons or the environment.
7.3 Lubrication and Lubricant Change

Under severe operating conditions, high ambient temperature, high humidity, dust laden air, aggressive industrial atmosphere,
etc. the intervals for checking, replenishing and replacing the lubricant should be shortened.
Oil Changes
 Refer to Section 6.1.1 “Bearing Lubrication” for bearing oil change instructions, specifications & capacities.
 The first oil change should be carried out after 300 operating hours, then every 3000 hours thereafter or when it appears
or is suspected of being dirty or contaminated.
 Drain the existing oil by removing the drain plug on the bottom of the housing.
 Reinstall the drain plug and fill with fresh oil until the oil level reaches the center of the oil sight gauge.
Grease Changes
 Refer to Section 6.1.1 “Bearing Lubrication” for bearing grease change instructions, specifications & capacities.
 Grease lubricated bearings should be replenished after the initial 50 hours of operation, then every 1,500 hours thereafter
by an injection roughly equal to one half of the amount originally used to pack the bearings.
 After 20,000 operating hours or 2.5 years the bearings should be checked, then cleaned and relubricated if required.
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7.3.1 Underwater Operation
Bearing assemblies for use underwater should be completely filled with oil and slightly pressurized by an oil recirculation and
filtering system. As a result, their capacities will be several times greater than detailed in Section 6.1.1 and a thinner oil will be
required. Depending upon the water temperature at the location at which the pumps are operating, the ISO viscosity grade
should be altered as follows for mineral oil-based lubricants:
For more information on Underwater Bearing Assemblies see Section 6.5 “Underwater Pump Operation”
7.4 Procedures for Maximum Parts Life

The wear of slurry pump parts is influenced by many factors and the following procedures are designed to help you get the
most out of your wet end wear parts. If problems occur, contact your GIW / KSB representative for a review of your application.
Suction Liner
 The suction liner should be rotated 180° at approximately half life if localized wear occurs. If localized wear is severe,
repair as recommended by GIW / KSB before rotation.
 If applicable, a new snap ring gasket or o-ring should always be used with a new suction liner or new pump casing.
Impeller
 The impeller to suction liner clearance should be adjusted forward several times during its life cycle for maximum impeller
and suction liner life. See Section 10.4 “Setting the Nose Gap”.
 In general, an impeller does not require replacement until it fails to produce sufficient head for the application. Impellers
are sometimes changed too soon based on appearance. Vibration caused by an impeller wearing out of balance is rare
but possible. If this occurs, the impeller may be statically balanced by hand grinding on back shroud.
 The impeller should never be repaired by welding.
Pump Casing
 If wear is localized with a deep gouge, repair or replace as recommended by GIW / KSB. Excessive wear problems are
usually indications that the pump is not operating at the flow and head conditions originally specified for the design.
Expeller Maintenance
 Proper adjustment of the impeller nose clearance as covered in the Section 10.4 “Setting the Nose Gap” should result in
proper expeller clearances in the new condition and no further adjustments should be necessary. In some cases adjusting
the impeller after excessive suction liner wear may result in the expeller rubbing against the expeller plate. In other cases
it is desired to optimize expeller performance rather than optimize the impeller clearance. Refer to Section 9.3.3 “Expeller
Running Clearance” for instructions.
CAUTION
Optimizing the expeller clearances is recommended only in cases where expeller performance is marginal
and a small increment in performance is required to seal against the pump pressure. Setting of
clearances for optimal expeller performance may result in excessive impeller clearance and accelerated
wear. If necessary, this may be remedied by providing a custom fitted machined spacer with gaskets
between the impeller and expeller.
7.5 Operational Problems and Solutions

Many pump wear problems are caused by unstable system operation, or off duty pump operation. Although the dynamics of
slurry piping systems cannot be fully addressed in this manual, the following items should be considered.
Refer to Section 12 “Toubleshooting” for additional information.
Sump Design / Supply Tank

 A minimum sump capacity of one minute at the expected flow conditions should be provided. Sump design should prevent
any uneven flow of the solids to the suction. Often, a flat bottom sump is best since it will allow the solids to assume a
natural slope of repose. The sump should be observed during operation to ensure that solids are not building up and
sloughing off.
 Sump design should prevent the formation of a vortex, or other means of introducing air into the pump. Where a
submerged suction is available, the depth of water level above the pump suction is more important than the cross-
sectional area of the sump. Frothing of the sump should be eliminated by the installation of baffles, a submerged inlet pipe
or other methods to prevent air becoming entrained in the slurry. If unavoidable, frothing must be accounted for in the
system design and operation.
 If the sump runs dry, the system will surge causing accelerated pump wear. Pump speed or impeller diameter should be
decreased or make up water increased. If the flow variations are too great, a variable speed motor may be required.
Cavitation / NPSH Performance

 The NPSH available must always be greater than the NPSH required by the pump or cavitation will occur resulting in head
loss (drop in discharge pressure), increased wear rate of the pump parts, and shock loading of the pump bearing
assembly. If any conditions occur, consult your GIW / KSB representative for the NPSH requirements of your pump.
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 To maximize the NPSH available to the pump, ensure that the suction line is as short and straight as possible and the
sump level is as high as possible, (or the suction lift as small as possible in the case of a pump located above the water
level). Minimizing the number of valves or short radius fittings and attaching a suction inlet bell will also reduce entrance
losses. A larger diameter suction pipe may help, but one must be careful not to reduce the flow velocity below safe
carrying levels or bedding of the slurry will occur and result in increased suction liner and impeller wear.
 In dredging applications where a free suction pipe or suction cutter head is lowered into the solids to be pumped, it is
useful to have pressure gauges attached to the pump suction and discharge. An operator, by observing the gauges, will
be able to maintain a maximum suction vacuum without cavitating the pump.
Piping System Design

 With coarse settling slurries, the pipelines should be vertical or horizontal. Inclined pipelines may surge due to a backward
drift or build up of solids. Also, an increase in slurry friction loss may be experienced in these sloped lines, further
reducing performance.
 Piping diameters must be properly sized to maintain sufficient carrying velocity. Oversized pipelines may result in the
formation of a sliding bed of slurry, which can greatly accelerate the wear of pumps and pipelines.
Operating Conditions of Flow and Head

It should be noted that the pump always operates at the intersection of the pump curve and the pipeline "system" curve.
During the initial stages of operation, motor load on the pump should be checked. If there is an excess amount of power being
drawn by the pump, it may be caused by the system head (TDH) being lower than predicted thus resulting in higher flow rates
and power consumption. This sometimes happens when a safety factor is applied to the head during the design of the system.
Cavitation may also occur under these high flow conditions. The pump speed should be slowed down to reduce flow, or the
total discharge head against the pump should be increased (resulting in reduced flow and power consumption).
If actual supply flow rates are lower than predicted, the sump may run dry causing the system to surge and accelerating pump
wear. Pump speed or impeller diameter should be decreased or make up water increased to keep the sump at the highest
stable level possible. If the flow variations are too great, a variable speed motor may be required. This problem is especially
common in applications with a high proportion of static head, such as mill discharge and cyclone feed. It can be further
aggravated by operation well below the best efficiency flow rate of the pump where the pump head curve is relatively flat.
Under these conditions, minor fluctuations in the system resistance caused by normal variations in solids concentration or size
can result in surging flow rates.
Whenever possible, avoid prolonged operation at flows well below the optimum flow rate. This causes recirculation of slurry
within the pump and encourages localized wear.
In the event problems are encountered, contact your GIW / KSB representative. The pump serial number, in addition to the
following, should be furnished to assist in evaluation of the problem:
A. Pump serial number (from the nameplate on the pedestal or bearing housing), customer location, and the approxi-
mate startup date.
B. Pumped fluid SG (specific gravity), slurry information including SG and particle size, and liquid temperature.
C. The approximate flow rate desired and the actual minimum and maximum flow rate of the system if known.
D. The system static head (the difference in elevation between the water level on the suction side of the pump and the
point of discharge)
E. The length and size of suction and discharge lines, including a description of the general arrangement including fit-
tings, bends and valves
F. If the discharge point is not to atmosphere, what is the pressure, (e.g. cyclone backpressure).
G. If suction is taken from a sump, provide the general arrangement including size dimensions and minimum and maxi-
mum sump levels referenced to the suction centerline of the pump.
H. The available driver horsepower, speed of motor and pump or description of the ratio device between the pump and
motor.
I. The impeller diameter if different from that supplied with the pump.
The above items of data are especially important when a pump has been transferred from the duty for which it was selected to
some other application.
In many instances, it will be found that unusual wear in the pump, or low efficiencies, are caused by a mismatch between the
pump and the system application and can be corrected once the operating conditions are known.
Contact your GIW / KSB representative for further specific recommendations regarding system design. A useful reference and
textbook has also been published by GIW titled: “Slurry Transport Using Centrifugal Pumps,” by Wilson, Addie & Clift.
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8 Mechanical End
8.1 Mechanical End Overview
 The bearing assembly is a cartridge design mounted on a concentric pedestal with an adjustment mechanism for setting
the impeller axial clearance.
 Standard lubrication is grease. Oil lube is also available. See Section 6.1.1 “Bearing Lubrication” for lubrication quality and
quantity.
 Basic bearing parts are listed below for reference. Note that the suffix can vary depending on configuration and vendor.
Replacement bearings are available from GIW/KSB.
Bearings Installed
Double Row Taper Roller - Back to Back Double Row Taper Roller - Face to Face
Bearing Spherical
Assembly Roller Part number Bench Part Number Bench
(Timken) End-Play (SKF) End-Play
E Type Cone / Cup / Spacer * mm (inch) mm (inch)
53177
35 mm 22209E 53376D 0.15 (0.006) 31309 J2/QCL7CDF 0.10 (0.004)
X2S53176
72225C
50 mm 22212E 72488D 0.15 (0.006) 31312 J2/QDF 0.12 (0.005)
X1S72225
9285
70 mm 22217E 9220D 0.18 (0.007) 31316 J1/QLC7CDF 0.14 (0.006)
X4S9285
HM926740
100 mm 22224E HM926710CD 0.25 (0.010) 31322 XJ2/DF 0.16 (0.006)
HM92674XA
HH932145
125 mm 22230E HH932110 0.20 (0.008) 31328 XJ2/DF 0.19 (0.008)
H932145XA **
* Koyo is also an approved supplier for the Back to Back Taper roller bearing.
** Assembled from two single row bearings.
Cartridge Bearing Assembly
8.2 Mechanical End Disassembly

GIW REGEN Service Centers remanufacture bearing assemblies and refurbish pumps.
GIW will rebuild your assembly and return it to its original specifications using genuine OEM replacement parts.
Contact your GIW Sales Representative for details.
WARNING
Refer to Section 2.9 “Assembly & Disassembly Safety” prior to working on the pump
 Drain the oil (if applicable) by removing the drain plug on the bottom of the housing.
 Remove the flingers (if any) and bearing housing end covers. Care should be taken with the Inpro oil seals, which should
not be removed from the end covers unless they have been damaged and are in need of replacement. Inspect the seals,
gaskets, and o-rings, and discard any that appear worn or broken.
 The locknut and lock washer that clamp the drive side bearing should also be removed. One tab of the lock washer will be
bent into a recess on the lock ring and must be bent back to allow the lock nut to be unscrewed.
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 The shaft and bearings (which are pressed onto the shaft) may then be removed as a unit from the drive end of the
housing. Horizontal disassembly is acceptable when proper support is given to the shaft to prevent its contacting and
marring any of the finished surfaces of the shaft or bearing housing bore. Care should be taken to avoid damaging the
grease retaining ring (part 63-7, grease lubricated) or spacer ring (part 45-4, oil lubricated) that will come out on the shaft
between the two bearings.
 The bearings are hot when installed on the shaft, and fit tight. It is difficult to remove them from the shaft undamaged, and
they should be removed only if a bearing needs to be replaced. Bearings are normally removed by heating, which should
be done quickly to prevent heating of the shaft as well. Flame cutting of the outer race and careful grinding of the inner
race may occasionally be required. Care must be taken, however, to avoid damaging the shaft, especially in the oil seal
area.
8.3 Mechanical End Assembly
WARNING
CAUTION
Before assembly, thoroughly clean all shaft, housing bore, and end cover surfaces with a suitable solvent to
remove old grease and any water, dust or grit. Clean all dismantled components and check them for signs of
wear. Damaged or worn components are to be replaced by original equipment spare parts. Make sure that the
seal faces are clean and the O-rings and gaskets are properly fitted.
8.3.1 Mounting the Bearings
WARNING
Care must be taken when handling heated components.
 Heat radial bearing (322) to 120 °C (250 °F) by a suitable bearing heater, oil bath, or other even heating device prior to
mounting. Flame heating is not recommended.
 Install radial bearing onto shaft
 Press fit bearing ensuring that it is seated fully against the abutting shaft shoulder.
 Use the bearing assembly drawing to determine if the bearing assembly uses the face to face or back to back taper
bearing arrangement.
Back to Back Taper Roller Bearing Face to Face Taper Roller Bearing
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Taper Bearing Locknut Assembly Torque
Locknut Assembly Torque
Bearing Assembly
N-m ft-lbs
35 mm 100 75
50 mm 135 100
70 mm 200 150
100 mm 375 275
125 mm 680 500
8.3.2 Back to Back Thrust Bearing Installation

 For grease: Install grease retaining ring 63-7 and ensure proper orientation.
 For oil: Install spacer ring 45-4 and ensure proper orientation.
Outboard Side Inboard Side
Cup
Cone
Grease
Roller Retainer
Ring
Spacer
Back to Back Thrust Bearing Arrangment Retainer Ring (Grease)
CAUTION
The grease retaining ring (63-7, for grease lubrication) or spacer ring (45-4, for oil lubrication) must be placed
on the shaft between the bearings, and in the proper orientation, before both bearings are mounted. Once the
bearings are mounted, they cannot be removed without risk of damage. The grease ring is essential in
protecting the taper bearing from loss of lubrication in the event of high loadings. Failure to install the ring may
result in significantly reduced bearing life.
 Heat inboard cone to 120 °C (250 °F) and install. Ensure that the larger OD of the bearing is towards the center of the
shaft.
 Install spacer and bearing cup
 A clip may be used to hold the cup in place.

 Heat the outboard cone to 120 °C (250 °F) and install. Ensure that the larger outer diameter of the bearing is towards the
drive end of the shaft.
 Before the taper roller bearing has cooled on the shaft, use the lock nut without lock washer to fully seat the bearing
against the shaft shoulder. (The lock washer must be left out during this step to prevent damage)
 After the bearings have cooled, remove the locknut and reinstall with lock washer against the taper roller bearing,
tightening the nut according to the torque given in Section 8.3.1 “Mounting the Bearings”.
 After tightening, bend down one tab of the lock washer into one of the mating grooves on the locknut. If none of the tabs
are aligned with a groove, locate the nearest one, and further tighten the locknut until the tab can be bent down.
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CAUTION
 Over-tightening can damage the lock washer and allow the locknut to back off during operation.
 Do not back off the locknut any amount after tightening in an attempt to set the bearing clearances.
The taper bearing has an internal spacer, which automatically sets the internal bearing clearances.
 Failure to bend down one of the lock washer tabs may allow the locknut to back-off and lead to
premature bearing failure.
 Ensure that the bearing outer diameters and housing bores are clean. Coat shaft between the bearings with GIW Blue
Synthetic Bearing Lubricant.
 Lift shaft vertically and place into housing from drive end. It will be necessary to align the grease ring 63-7 or spacer 45-4
as it enters the housing since it has about 6mm (0.25”) of clearance with the shaft.
CAUTION
The bearings should slide easily and fully into the bearing housing without excessive force that would indicate
possible dust or grit between the bearings and the housing, and result in a thrust preloading on the impeller
end spherical roller bearing. Preloading of the bearing will cause it to carry thrust loadings, which would
normally be carried by the taper roller bearing and can result in overheating and premature failure of the
spherical roller bearing.
8.3.3 Face to Face Thrust Bearing Installation

 Place the cup of the inboard bearing onto the shaft.
 Heat the inboard cone to120°C (250°F) and press fit onto the shaft.
 Heat the outboard bearing cone to 120 °C (250 °F) and press fit onto the shaft.
Outboard Side Inboard Side
Cup
Spacer Cone
Roller
Face to Face Thrust Bearing Arrangment
 After both cones are installed and before the taper roller bearing has cooled on the shaft, use the lock nut without lock
washer to fully seat the bearing against the shaft shoulder. (The lock washer must be left out during this step to prevent
damage)
 After the bearings have cooled, remove the locknut and reinstall with lock washer against the taper roller bearing,
tightening the nut according to the torque given in Section 8.3.1 “Mounting the Bearings”.
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CAUTION
 Over-tightening can damage the lock washer and allow the locknut to back off during operation.
 Do not back off the locknut any amount after tightening in an attempt to set the bearing clearances.
The taper bearing has an internal spacer, which automatically sets the internal bearing clearances.
 Failure to bend down one of the lock washer tabs may allow the locknut to back-off and lead to
premature bearing failure.
 After tightening, bend down one tab of the lock washer into one of the mating grooves on the locknut. If none of the tabs
are aligned with a groove, locate the nearest one, and further tighten the locknut until the tab can be bent down.
 Failure to bend down one of the lock washer tabs may allow the locknut to back-off and lead to premature bearing failure.
 Ensure that the bearing outer diameters and housing bores are clean. Coat shaft between the bearings with GIW Blue
Synthetic Bearing Lubricant then lift shaft vertically and place into housing from drive end.
 Insert the spacer and cup for the outboard bearing using a rubber mallet.
CAUTION
The bearings should slide easily and fully into the bearing housing without excessive force that would indicate
possible dust or grit between the bearings and the housing, and result in a thrust preloading on the impeller
end spherical roller bearing. Preloading of the bearing will cause it to carry thrust loadings, which would
normally be carried by the taper roller bearing and can result in overheating and premature failure of the
spherical roller bearing.
Inserting the Spacer and Cup
Bearing Assembly inserted into Housing Drive End Use a rubber mallet to ease insertion
8.3.4 Installing End Covers and Seals

 The standard bearing housing shaft seal is the Inpro VBX type labyrinth seal. Other seal types may be available including
the Caterpillar Duo-Cone seal for underwater bearing assemblies. See your arrangement drawing for specific information
regarding these alternate seal types.
 Prior to installation, press the Inpro shaft seals into each end cover, ensuring that the contaminant expulsion port and
lubrication return trough are located at the 6 o’clock (bottom) position. If possible, use a hand operated arbor press
instead of a hydraulic press to improve control of the pressing operation. You will be overcoming a light interference fit
and may shear off a portion of the outer diameter o-ring, however, this is normal and indicates a secure fit.
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LCC
Install with lubrication return trough at 6 o’clock position VBX Inpro Seal
 Slide end covers with gaskets and Inpro seals over the shaft at each end, again making certain that the contaminant
expulsion port and lubrication return trough are located at the bottom. Use O-Ring lubricant, Parker O-Lube or Parker
Super-O-Lube to lubricate the inner diameter o-rings against the shaft. Take special care when running the seal over the
shaft keyway to avoid cutting the o-ring. If necessary, lightly file the keyway edges to avoid this problem.
 After bolting the end covers in place, rotate the shaft by hand. There should be no frictional contact between the rotating
and stationary parts of the Inpro seal. Any rubbing or axial movement in the seal may indicate misalignment. If this is the
case, tap lightly into alignment. Note that the drive side end cover clamps against the outer race of the taper roller bearing
and may not fit flush against the housing. No shimming is necessary. A gap of up to 1 mm (0.04”) is acceptable and within
the tolerance of the parts. Any larger gap may indicate that the taper roller bearing is not fully seated into the housing.
 Install grease fittings or oil plugs.
8.4 Bearing Assembly Mounting

 After mounting the stuffing box (or mechanical seal adapter) loosely onto the pedestal plate, and screwing the adjusting
screw (909) with nut (924) an appropriate length into the pedestal, the cartridge bearing assembly may be placed onto the
pedestal saddle. Note that the slotted tab on the housing must be inserted between the adjusting screw shoulder and the
adjusting nut.
 The pedestal and bearing housing saddles should be clean, dry, and free from oil or grease. If corrosion of the saddles is
a problem, apply a thin film of preservative. Special care must then be taken in the axial adjustment procedure to ensure
that no movement may occur. See the Section 10.4 “Setting the Impeller Nose Gap” for more details.
 The four bearing housing hold down clamps (732) may now be bolted on, but should remain slightly loose until the axial
adjustment of the bearing housing is complete.
 Fastener torque must be accurately measured to achieve the proper clamping force. Air impact wrenches rarely deliver
the correct torque due to variations in air pressure and tool condition. These can be used to tighten the bolts, but the final
torque values should be achieved with a calibrated torque wrench. The use of a Hydraulic Torque Wrench is
recommended for larger fasteners, and these tools can be calibrated to produce the necessary accuracy.
WARNING
Failure to install the bearing housing hold down bolts at this time may result in tipping of the bearing assembly
and possibly personal injury when the impeller is screwed on to the shaft.
Bearing Assembly Clamp Bolts

Bearing Clamp Bolt Torque
Bolt Size
Assembly N-m ft-lbs
35 mm
M20 340 250
50 mm
70 mm
100 mm M24 680 500
125 mm
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LCC
9 Shaft Seal
9.1 Mechanical Seal
CAUTION
Mechanical seals require safety checks prior to start-up such as removing seal assembly fixtures, checking
axial alignment, checking torques etc. Refer to the mechanical seal operating manual for all required safety
checks.
Mechanical seals are precision devices which require special care for their proper operation. The instruction manual for the
seal should be consulted for special storage, start-up, and maintenance requirements.
For information on mechanical seals, consult the manufacturer’s manual.
Example Mechanical Seal cross section
9.1.1 Mechanical Seal Assembly and Disassembly

Review the mechanical seal arrangement and determine the layout of the mechanical seal assembly. Some mechanical seals
have an adapter which must be placed on the shaft before the hub plate and/or casing is installed while others can be installed
after the casing is installed.
Always refer to the mechanical seal maintenance manual for further instructions.
9.2 Stuffing Box

GIW offers three stuffing box designs. In general, more flush water will result in less wear on the packing and sleeve, so the
decision of which design to use depends on the severity of the service, quality of the seal water and relative importance of seal
life vs. water supply costs.
 The Throat Bushing design is the standard product offering in GIW’s LSA style S & SC pumps. It combines the lantern
ring with a longer, tight tolerance collar and provides a compromise between the Forward Flush and KE designs in difficult
applications where water reduction is needed. It produces a throttling effect that restricts seal water flow in the pump while
maintaining pressure and flow at the packing rings. This reduces the amount of water that enters the process flow while
providing an easy-to-maintain stuffing box assembly. The Throat Bushing design is also available in a variation
incorporating the SpiralTrac™ technology. This allows for flowrates to be reduced by more than 50% when compared to
the less efficient Forward Flush boxes, while still maintaining acceptable packing life and shaft sleeve wear.
 The KE design is used where minimum water usage is desired. One or two rings of packing are located between the
lantern ring and the wear plate to restrict seal water flow into the pump cavity, while the packing rings behind the lantern
ring seal to atmosphere. It is the most sensitive design to variable operating conditions and abrasive wear, and requires
more careful maintenance.
 The Forward Flush design design has historically been used where gland water supply is plentiful, and the addition of
water to the process flow is not problematic; however, please note that GIW is phasing out the Forward Flush design
stuffing box due to global water conservation initiatives. This stuffing box is no longer available on GIW’s S and SC
pumps.
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LCC
Packing Packing Packing
Throat Bushing Lantern Ring Lantern Ring
Throat Bushing KE Design Forward Flush
9.2.1 Stuffing Box Packing

Stuffing box packing is the actual sealing element in most stuffing box assemblies. It experiences considerable friction and will
have a limited lifespan. Proper maintenance procedures are essential to avoid premature failure, wear and corrosion to nearby
parts, mechanical end contamination and unnecessary downtime. The following provides an introduction to packing basics.
Refer to your GIW Pump Maintenance Manual, GIW representative and/or packing supplier for further detail.
The packing type must be compatible with your pumping application. This includes pressure, temperature, pH and solids
content. Seal water quality can also affect packing selection. Refer to your Bill of Materials for the packing type supplied with
your pump or contact your GIW representative if a change in packing type is needed.
Summary of standard GIW packing types:

Tuf-Pak 100
Vegetable fiber packing impregnated
with PTFE for moderate temperature,
pressure and pH.
Tuf-Pak 500
Tuf-Pak 300
Graphite particles in an expanded
Continuous filament polyimide and
PTFE matrix plus aramid corner braid
PTFE yarns for high temperature or
for high pressure application with hot
pressure and wide range of pH.
and/or poor quality seal water.
Tuf-Pak 400
Tuf-Pak 600
Graphite particles in an expanded
Heat resistant, thermoset fiber for most
PTFE matrix for extreme chemical
applications. Commonly supplied with
service and grease lubricated expeller
SpiralTrac™ assemblies
seals.
9.2.2 Stuffing Box Assembly

The stuffing box should be mounted so that the sealing water tap is on or near the horizontal centerline. This will position the
gland studs at 9 o’clock and 3 o’clock for easy access on smaller shaft sizes. Note that the small stuffing boxes have a single
inlet while the larger sizes have a second port that can be used for additional flow or have a pipe plug installed.
Clearance is provided between the stuffing box rabbet fit and the pedestal to allow centering of the stuffing box to the shaft
sleeve. During installation, the packing space should be equalized to within 0.25 mm (.010”) at all locations before fully
tightening the stuffing box flange bolts.
In some cases, a separate stuffing box wear plate may be provided. This should be fastened into place with a fresh gasket.
CAUTION
Failure to center the stuffing box may result in greatly reduced service life for the packing and shaft sleeve.
9.2.3 Stuffing Box Maintenance

 The stuffing box is equipped with tapped holes for sealing water located 180° apart. Either tap can be used; however,
normal practice is to pipe sealing water to both taps.
 In order to keep the stuffing box free from abrasive particles, the sealing water pressure and gland (452) tightness should
be adjusted to maintain a small flow of cool or lukewarm leakage out of the stuffing box. If the leakage becomes hot, the
gland should be loosened to allow a greater flow. If cloudiness is seen in the leakage, greater water pressure is needed.
 For gland flush supply, use suitable non-aggressive clean water not liable to form deposits and not containing suspended
solids. Hardness should average 5 with a pH > 8. It should be conditioned and neutral with regards to mechanical
corrosion.
 An Inlet Temperature of 10 °C – 30 °C (50 °F – 85 °F) should produce a maximum Outlet Temperature 45 °C (115 °F)
when the gland is properly adjusted.
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LCC
 The sealing water pressure required to maintain satisfactory stuffing box operation will vary with pump operating pressure,
slurry properties, condition of the packing, and the type of stuffing box. A supply pressure of 10 psi (0.7 bar) over the
discharge pressure of the pump should be available. In most cases, adjustments to supply pressures can be made with a
manual valve and gauge near the stuffing box.
Flow Control Option

 The KE stuffing box is a Low Flow design and must be pressure controlled. Flow control can result in burning or jamming
the packing. Actual flow in a properly maintained and adjusted stuffing box is considerably less than shown in the Table.
 Forward Flush and Throat Bushing stuffing boxes are generally pressure controlled, but flow control is an option. Seal
water requirements listed in the table show potential flow with worn packing.
 Flow control may be achieved in different ways. A Positive Displacement pump that delivers the correct volume can be
used with a safety or “pop-off” valve so the purge pressure can never exceed 10 psi (0.7bar) above the Maximum Working
Pressure of the pump. Where water supply is adequate, install a flow meter and regulating valves in the line. A backflow
preventer is recommended to prevent reverse flow should the pump pressure exceed supply pressure. All components
must have adequate pressure ratings. Verify that components will work with the volume, pressure and water quality
supplied to the stuffing box.
 For best performance each pump should be adjusted for minimum water consumption while still providing adequate drip
rate. As the volume of water is reduced, the stuffing box gland will need to be loosened slightly to maintain the proper drip
rate. This will ensure adequate flush while limiting water use. The temperature of the water exiting the stuffing box can be
a better indicator than “drip rate” or volume. This should be at a temperature that would be comfortable for hand washing
which indicates that the packing is not overheated.
Stuffing Box Maximum Seal Water Requirements

 For hot, high pressure or otherwise severe service conditions, an optional combination lantern ring / throat bushing is
recommended in place of the standard lantern ring and first ring of packing. Water requirements for this option will be
about mid-way between the forward flush and KE configurations shown in the table below.
 For expeller applications, the stuffing box used must be of the ‘KE’ (low flow) type with a ring of packing between the
lantern ring and pumped fluid. All rings of packing should be well coated with water resistant grease during assembly.
Stuffing Box Type

Shaft Throat
KE Design Forward Flush *SpiralTrac™
Size Bushing
L/sec (gpm) L/sec (gpm) L/sec (gpm) L/sec (gpm)
35mm 0.18 (2.8) 0.09 (1.4) 0.44 (7.0) 0.09 (1.4)
50mm 0.21 (3.4) 0.11 (1.7) 0.54 (8.5) 0.10 (1.7)
70mm 0.30 (4.8) 0.15 (2.4) 0.76 (12.0) 0.15 (2.4)
100mm 0.39 (6.2) 0.20 (3.1) 0.98 (15.5) 0.19 (3.1)
125mm 0.47 (7.4) 0.23 (3.7) 1.17 (18.5) 0.23 (3.7)

*Non-standard option
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LCC
9.3 Expeller Seal
Expeller seals are used in pump applications where limited
or no gland flush water is readily available or where it is not
compatible with the process fluid. A second rotating impeller
contained in a separate expeller casing creates a lower
pressure at the stuffing box seal area. This allows the shaft
sleeve to be grease lubricated and run with only enough
packing compression to seal the pump.
Unlike mechanical seals, expellers must be carefully Metal Seal Ring

selected for each application and specific operating
conditions. Expellers require additional driver horsepower,
which must be accounted for during motor selection.
Changes to head, flow, pump speed, process solids or sump
level after the pump has been installed can affect the
functionality of an expeller sealing system.
Correct installation, adjustment and operating procedures

are extremely critical to the proper function and life of these
seals. Extensive testing has shown that the following
guidelines can help keep the expeller system operating
properly while prolonging the life of wear components.
Further engineering review is recommended for expeller
operation outside these guidelines.
Particle size – The D50 should be kept between 200 and

1500 microns.
Slurry SG – The Specific Gravity of the slurry should remain

below 1.35.
Solids – Slurries that could deposit scale on pump surfaces Typical Expeller Arrangement
should be avoided.
Flow rate – Stay between 0.5 and 1.3 times the Best Efficiency Point (QBEP).
Flushing – Solids in the process flow can precipitate out when the pump stops and build up in the expeller chamber. Over
time, this reduces efficiency and accelerates wear. The system should always be purged with clear water for at least 15
minutes prior to stopping the pump. Starting the system on clear water will help the expeller displace solids. For applications
where precipitate buildup in the expeller chamber is unavoidable, intermittent gland water flush may be necessary.
When the stuffing box does not have flush water, the packing must be lubricated with grease or oil. Graphite packing such as
Tuf-Pak 400 is recommended. Manual or automatic grease dispensers are available depending on the application. Twisting
the cap in on the manual units will add a small amount of grease to the packing. These are refilled by removing the cap and
packing the cup with lubricant. Automatic greasers use a spring driven piston to maintain a steady supply of grease. These are
refilled by connecting a grease gun to the fitting on the side of the unit. Note that extremes in temperature can alter the amount
of lubricant supplied to the packing and must be accounted for. Springs are available for the automatic greaser with three
different tension levels to control the flow of grease.
New expeller pumps are equipped with a diverter ring pressed into the hub area of the pump casing. This acts as a baffle to
help reduce the amount of solids entering the seal chamber. The diverter can be ordered as a service part and retrofit into
earlier units. For diverter installation see supplement 11.4.
It is important to operate the expeller pump within the speed limitations and operating conditions specified in the original
design parameters. Wide variations in flow rate and solids can allow particles to accumulate in the expeller chamber, which
may result in a plugging or premature component failure. Any change in the operating conditions should be discussed with
your GIW / KSB representative to establish if the new conditions are suitable for the equipment.
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LCC
9.3.1 Expeller Assembly
WARNING
If attempt is made to mount the expeller plate without the support of the pump casing or expeller casing studs,
it will not be properly supported and may fall without warning.
For 2x3 and 3x4 LCC-M Pumps

 Before mounting the expeller (23-15) a 0.5 mm (0.020 inch) aramid gasket (400.31) is placed between the shaft sleeve
and the expeller to prevent galling and ensure ease of removal. The gasket should be installed dry, without grease.
 Mount the expeller casing (10-7) to the pedestal using two spare bolts (not provided) at 180 degrees to each other to hold
it temporarily in place.
 After mounting the expeller, which is a close sliding fit to the shaft, adjust the bearing assembly towards the drive end until
the expeller just begins to rub on the expeller casing. Then move it back towards the pump end approx. 1.0 mm (0.4 inch).
This is a preliminary adjustment. Final adjustment will be made after wet end assembly is complete.
 Mount the expeller plate (16-4) at the same time the pump casing or expeller casing is mounted by inserting the studs into
the pump casing or expeller casing and allowing the expeller plate to rest on and be supported by the studs.
For LCC-R, LCC-H, and all other LCC-M Pumps

 Before mounting the expeller (23-15) a 0.5 mm (0.020 inch) aramid gasket (400.31) is placed between the shaft sleeve
and the expeller to prevent galling and ensure ease of removal. The gasket should be installed dry, without grease.
 Mount the expeller casing (10-7) to the pedestal using two hex head bolts (901.13) at the 3 & 9 o’clock positions with the
bolt heads on the expeller casing side.
 After mounting the expeller, which is a close sliding fit to the shaft, adjust the bearing assembly towards the drive end until
the expeller just begins to rub on the expeller casing. Then move it back towards the pump end approx. 1.0 mm (0.4 inch).
This is a preliminary adjustment. Final adjustment will be made after wet end assembly is complete.
 Mount the expeller plate (16-4) to the pump casing using two hex head bolts (901.14) at the 3 & 9 o’clock positions. Mount
the expeller plate and pump casing to the expeller casing and pedestal by inserting studs into the remaining stud
positions. Hex head bolts at the 3 & 9 o’clock positions should not be removed or replaced with studs.
9.3.2 Expeller Disassembly
WARNING
If not removed in the manner described below, the expeller plate may fall without warning after the pump
casing is removed.
For 2x3 and 3x4 LCC-M Pumps

 After supporting the pump casing, remove the nuts from all four of the studs (902.10) which hold the pump casing in
place.
 Dismount the pump casing and the expeller plate (16-4) together, allowing the expeller casing to rest on and be supported
by the 4 studs.
 Go to the “Removing the Expeller” section below.
For LCC-R, LCC-H, and all other LCC-M Pumps

 After supporting the pump casing, remove the nuts from all six of the studs (902.10), which hold the pump casing in place.
This excludes hex head bolts at the 3 & 9 o’clock positions which mount the expeller plate to the pump casing (901.14)
and expeller casing to the pedestal (901.13).
 Dismount the pump casing and the expeller plate (16-4) together.
If not removed in the above manner, the expeller plate may fall without warning after the pump casing is
removed.
Removing the Expeller

 Before removing the expeller, ensure that the 2 bolts in the 3 & 9 o’clock positions (901.13) that secure the expeller casing
(10-7) to the pump pedestal have not been removed.
 For 2x3 and 3x4 LCC-M, use two of the holes left open and two spare bolts (not included) to secure the expeller casing
(10-7) to the pump pedestal.
If not secured in the above manner, the expeller casing may fall without warning after the expeller is removed.
 The expeller (23-15) may now be removed from the shaft. The fit of this part is similar to that of a shaft sleeve (a close
sliding fit). If necessary, the expeller casing may be unfastened from the pedestal, supported as needed and used to apply
pressure to the expeller in order to force it from the shaft. This pressure must be applied at several points around the
expeller casing to prevent uneven loading and potential breakage of the hard iron parts.
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LCC
9.3.3 Expeller Running Clearance
The following procedure is recommended for optimizing expeller performance or for setting the clearances in pumps
containing any worn parts:
1. With the suction plate/liner removed, adjust the bearing assembly toward the pump end until the back surface of the
expeller just begins to rub the expeller plate.
2. Mount a dial gauge to indicate cartridge bearing assembly axial movement and zero the dial gauge at this location.
3. Now adjust the bearing assembly toward the drive (or motor) end until the expeller vanes just begin to rub on the expeller
casing, or the impeller begins to rub on the hub side of the pump casing, whichever comes first.
4. Adjust the bearing assembly toward the pump end again approximately 1.0 mm (0.04 in.) to provide a minimal expeller
running clearance. If optimization of expeller performance is desired, lock the adjustment at this location
5. Reassemble the suction plate and check the impeller to liner clearance. If not optimizing expeller clearances set the
impeller clearance as detailed in the section “Axial Adjustment of the Bearing Housing”. Do not allow the dial gauge to
come closer than 1.0 mm (0.04 in.) to the original zero setting or expeller rubbing may occur. If necessary, consider the
use of a spacer as mentioned in step 4.
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LCC
10 Wet End
10.1 Wet End Overview
10.1.1 Pump Casing
Three standard configurations are available:
1 Hard Metal. Single-wall casing, impeller and suction liner of high-chrome white iron. Suitable for high-discharge head, all
particle sizes up to maximum sphere passage and mildly corrosive slurries. Custom materials available for highly corrosive
slurries.
2 Elastomer Lined. Radially split construction with ductile iron outer casing and molded-elastomer inner liners. Impeller of
high chrome white iron or polyurethane. For moderate discharge head, fine to medium particles and highly corrosive slurries.
3 Extra Heavy Hard Metal. Similar to hard metal version, but with heavier sections and hydraulics suited to the most severe
slurry duties. Two-stage pressure capability. Available in sizes LCC 150 - 500 and above.
All casings carry 125 pound, ANSI flange bolting patterns. Adapters for conversion to DIN flanges are available.
Hard Metal Elastomer-Lined Extra Heavy Hard Metal
10.1.2 Impeller Form

All standard impellers are 3 vane, double shrouded designs. Open-shrouded and alternate vane number designs are available
in some sizes.
10.2 Wet End Disassembly
WARNING
DANGER
Do not apply heat to the impeller hub or nose due to the sealed cavity at the impeller nose.
DANGER OF EXPLOSION!
10.2.1 Impeller Removal

During normal operation, the impeller becomes tightly screwed onto the shaft by the running torque. A steady torque or mild,
yet sudden, torsional jolt is usually required to disengage the impeller. Several methods of achieving this end are possible.
One of the easiest methods is outlined below. To order the jigs described here, contact your GIW / KSB representative. Please
provide your pump assembly number with the order to ensure a good fit.
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LCC
10.2.2 Impeller Break-Loose Jig
WARNING
Energy can be released during disassembly of the tightened Impeller. Break Loose Jig
Break loose jigs, lifting jigs and Impeller release rings could spring
suddenly and injure nearby personnel. Impeller
 Rotate the impeller until the tip of one blade is facing the pump discharge.
 Insert the jig through the eye of the impeller and attach to trailing edge of blade facing
discharge.
 Rotate the shaft in the direction opposite to normal, using the pump pulley or a
spanner wrench.
 For ease of impeller removal, the shaft threads should be heavily coated with anti-
seize compound during re-assembly. Two aramid paper gaskets should be used
between the shaft sleeve and the impeller.
10.2.3 Impeller Lifting Jig
WARNING
Do not remove, lift, move or reinstall Impeller without properly using a recommended Impeller lifting jig.
 For impeller removal or installation, grasp the impeller at the suction eye. The impeller can be leveled by turning the
adjusting bolt which bears against the impeller nose. This is especially useful during re-installation.
 For impeller removal ensure that the lifting line is tight prior to thread disengagement.
Impeller Lifting Jig
10.2.4 Casing Removal

It is recommended that at least two lift points be used when moving any pump casing. This permits greater safety and control
of the component. Where applicable, GIW pump casings are supplied with cast lifting eyes for this purpose. Note that if the
chain hook does not fit the lifting eye, an appropriate clevis should be installed. Another acceptable lifting point is a chain
secured around the discharge flange, being careful not to damage the bolt flanges.
10.2.5 Elastomer-Liner Removal

Most liners fit snug into the casings. Two threaded push-off holes at 180 degrees are provided in the casings to aid in removal.
If reuse of the liners is anticipated, care must be taken to push the liners out evenly to avoid bending of the steel backing plate.
10.3 Wet End Assembly
WARNING
Refer to Section 2.9 “Assembly & Disassembly Safety” and appropriate shaft seal drawing prior to
working on the pump
10.3.1 Mounting the Shaft Sleeve

 A light coat of anti-seize can be applied inside the shaft sleeve
 Do not allow anti-seize compound to come in contact with any of the axial faces of the shaft sleeve, including the impeller
contacting face and the face in contact with the shaft shoulder.
 When installing the shaft sleeve, stop when the sleeve face and shaft face are approximately 1 " apart. Inspect the faces
to be sure they are still clean and free from grease. If grease is present, the faces must be cleaned before the sleeve is
slid into place.
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LCC
 In many cases, there will be an o-ring which must be placed on the shaft first. As the shaft sleeve is pushed into position,
this o-ring should be completely forced into the shaft sleeve recess.
10.3.2 Mounting the Casing

 The alignment of the pump casing with the mechanical end is obtained through a rabbet fit machined into the pedestal.
For the best wear and efficiency performance, it is essential that the casing be fully seated in this fit.
 Ensure that the proper gasket is fitted between the casing and pedestal before installing.
 In the case of the elastomer lined LCC-R pump, the liner itself forms the seal. See below for additional instructions.
10.3.3 Elastomer Lined Wet End

 Firmly seat the liners into the metal casings using a large rubber mallet if necessary. To seat the suction side liner, use a
wooden brace and large C-clamps, or lay the liner, flange side up, on a wooden brace and lower the metal casing onto it,
allowing the weight of the casing to seat the liner. Seat the elastomer flanges into their grooves using a blunt tool if
necessary.
 The close fit of the liners, although requiring some effort in assembly, will ultimately ensure better liner support, and longer
wear life. If desired, liquid soap may be used to lubricate the liners during assembly.
CAUTION
Do not use petroleum-based products to lubricate the liners since they can cause degradation of the
elastomer.
 Before assembling the casing halves together, check the fit of the liners in the casing to ensure that they are seated
correctly, especially in the suction, hub, and discharge flange areas. Clearance allowing for limited readjustment of parts
has been provided in the holes through which the liner studs protrude.
 When bolting the casings together, ensure that the liners remain well aligned with each other on their outer perimeter,
especially in the discharge area. Some bulge may occur at the seam on the discharge flange. This may be removed, and
the sealing surface restored to flatness by lightly buffing with a coarse grade sand paper or grinding stone. If desired,
rubber gaskets may be applied at both the suction and discharge flanges, although this is typically not necessary.
 Some bulging may also occur inside the casing between liners. This is normal and does not affect performance.
10.3.4 Installing the Impeller

 Coat the shaft threads heavily with anti-seize compound. Do not coat the shaft sleeve faces which contact the impeller
and the step in the shaft.
 Two 0.5mm (0.020 inch) aramid gaskets (400.10) are placed between the shaft sleeve and the impeller hub face to
prevent galling and to ensure ease of impeller removal. Stagger the gaskets so they are not in alignment. The gaskets
should be installed dry, without grease.
 Screw on the impeller tightly by hand. With larger sizes, it may be convenient to hold the impeller stationary while turning
the shaft. Impeller lifting jigs are available to assist in this operation.
 When assembly of the pump is complete, check the impeller to suction wear plate clearance and adjust if necessary, (see
section on Axial Adjustment of Bearing Housing).
Staggered Impeller Gasket Installation
10.3.5 Suction Plate & Liner (LCC-H only)

 Bolt the suction liner to the suction plate and install o-ring before mounting to casing.
 After mounting, the suction liner should protrude approximately 1.0 mm (0.04 inch) from the suction plate at the suction
flange connection. This is normal and provides the sealing surface for the suction piping.
 It is important that excessive force is not placed on the liner by using a raised face flange or a gasket that covers the liner
protrusion only. In general it is recommended that a full face flange and full face gasket is used to connect the suction
piping.
43
LCC
Flange
Gasket Flange
Suction
Liner Flange Suction
Liner Flange
Gasket
Correct flange gasket installation Inproper flange gasket installation
10.4 Setting the Nose Gap

In order to maximize the performance of your pump, the clearance between the suction face of the impeller and the suction
liner must be adjusted to an allowed minimum depending on the size and type of bearing assembly. This is done by moving
the bearing housing assembly with the adjusting screw.
 Before adjustment may proceed, the pump wet end must be completely assembled.
o Stuffing Boxes may be packed before or after the adjustment procedure.
o Mechanical seal axial set must be left until after the adjustment is complete.
o Pumps with urethane or rubber lined parts should also have the suction spool or suction piping installed and
torqued prior to nose gap adjustment.
 Ensuring that all of the bearing housing hold down bolts are slightly loosened
 Run the bearing assembly towards the impeller end by means of the adjusting screw until the impeller first begins to rub
the suction liner. It is helpful to slowly rotate the impeller during this procedure.
 Reverse the adjusting screw until the clearance between the impeller and the suction liner is brought to the recommended
values shown in below.
 Once the clearance is correct, tighten the bearing housing hold down bolts according to the requirements of Section 8.4
“Bearing Assembly Mounting” and recheck clearance.
 Once the clearance is correct, lightly tighten the bolts of the four bearing housing clamps by hand, making sure that
proper contact is maintained at all four locations. Next fully tighten the bolts according to the requirements of Section 8.4
“Bearing Assembly Mounting” and recheck clearance.
 Finally, firmly lock the adjusting screw and nut together against the bearing housing tab.
CAUTION
The final movement of the bearing housing during adjustment should always be away from the impeller end,
as described above. This ensures that the threads of the adjusting screw will contain no backlash against the
forward directed thrust loading that the pump will generate during operation. It is especially important that this
convention be followed when a mechanical seal is being used.
Recommeded Recommended
Shaft Minimum Nose Minimum Nose Gape
Size Gap for Urethane Liners(1)
inch (mm) Inch mm
(3)
0.0001 x Urethane Thickness(2) x ∆T(°F)(3)
0.00018 x Urethane Thickness x ∆T(°C)

+ Recommended Nose Gap
+ Recommended Nose Gap

(2)
Impeller
All Sizes 0.010 (0.25)
Suction Liner
Urethane Thickness
Nose Gap
Example LCC cross-section shown
(1)
Additional nose gap required to account for thermal expansion of urethane.
44
LCC
(2)
Measure urethane thickness at nose gap location.
(3)
∆T = Operating temp – Ambient temp.
45
LCC
11 Tooling
11.1 Torque Requirements
Torque requirements listed below and in previous sections are for lubricated bolting. All bolts must be lubricated to ease in
pump assembly and disassembly. Anti seize compound is preferred, but well oiled is also acceptable.
Special Torque Requirements

 Fastener torque must be accurately measured to achieve the proper clamping force as defined either on the assembly
drawing or previous sections listed below. The use of a Hydraulic Torque Wrench is recommended as these tools can be
calibrated to produce the necessary accuracy.
 For bearing housing hold down bolt torque refer to Section 8.4 “Bearing Assembly Mounting”.
 If the pump is equipped with an impeller release ring refer to 10.3 “Wet End Assembly” for torque requirements.
 If the pump is equipped with a mechanical seal is used refer to the Mechanical Seal Manual for torque requirements.
Non-Critical Torque Requirements

No special torque requirements exist for the remaining nuts and bolts unless specifically called for on the assembly drawing.
Bolts and nuts for which torque is not specified should be tightened enough to ensure a firm mating between parts in
accordance with good maintenance practice. Where possible, the use of an air driven impact wrench is recommended for bolts
over one inch (25 mm) in diameter.
Recommended Fastener Torque Values for Non-Critical Fasteners

ENGLISH METRIC
Anti-Sieze Lubricated / Oiled Anti-Sieze Lubricated / Oiled
Pump Mounting Pump Mounting Pump Mounting Pump Mounting
Assembly Equipment to Assembly Equipment to Assembly Equipment to Assembly Equipment to
Size Fasteners Sub Base Fasteners Sub Base Size Fasteners Sub Base Fasteners Sub Base
lb-ft N-m lb-ft N-m lb-ft N-m lb-ft N-m lb-ft N-m lb-ft N-m lb-ft N-m lb-ft N-m
1/4" 3 5 5 6 5 6 7 9 M8 8 11 10 14 10 15 16 20
3/8" 12 17 17 23 19 25 25 35 M10 15 21 20 28 20 30 30 40
1/2" 30 40 40 55 45 60 60 85 M12 25 35 35 50 40 50 55 75
5/8" 60 80 85 115 90 120 125 170 M16 65 90 90 125 100 130 135 180
3/4" 105 145 150 200 160 215 220 300 M20 130 180 180 250 195 265 270 370
7/8" 175 230 240 325 250 350 360 485 M22 175 250 240 335 260 360 370 500
1" 260 350 360 490 385 520 540 730 M24 225 315 305 425 335 450 470 640
1 1/8" 320 430 445 600 470 645 660 900 M27 325 455 440 615 490 660 680 925
1 1/4" 450 610 620 850 670 910 940 1,275 M30 450 625 605 850 670 910 940 1,270
1 3/8" 590 800 825 1,115 880 1,195 1,225 1,670 M36 780 1,090 1,060 1,480 1,170 1,600 1,640 2,220
1 1/2" 780 1,060 1,090 1,480 1,170 1,585 1,635 2,220 M38 920 1,285 1,250 1,740 1,375 1,865 1,930 2,615
1 3/4" 915 1,240 1,280 1,735 1,370 1,850 1,920 2,600 M39 995 1,390 1,350 1,885 1,490 2,020 2,090 2,830
2" 1,375 1,864 1,925 2,610 2,060 2,795 2,885 3,910 M42 1,245 1,740 1,685 2,360 1,865 2,530 2,610 3,540
2 1/4" 2,010 2,726 2,815 3,815 3,015 4,085 4,220 5,725 M48 1,860 2,610 2,525 3,540 2,795 3,790 3,910 5,300
2 1/2" 2,750 3,729 3,850 5,220 4,125 5,590 5,775 7,825 M64 4,445 6,220 6,025 8,440 6,670 9,040 9,335 12,650
Values based on Grade 5 fasteners
Torque Values taken at 50% Proof Strength for Pump Assembly Fasteners
70% Proof Strength for Mounting Equipment to Sub Base
K-Factors = 0.120 for Anti Sieze
0.180 for Lubricated / Oiled
46
LCC
11.2 Spare Parts Stock
Due to the erosive action of the slurry, many of the wet end components of the pump may require replacement during normal
maintenance. Inspection or overhaul of the mechanical components may also require the replacement of certain parts.
The following are recommended lists of parts (whenever applicable) to have on hand for normal maintenance and inspection.
The quantities of parts kept in store will depend upon the severity of the slurry duty and the number of units operating.
Maintenance practices may also favor keeping fully built sub-assemblies or complete pumps on hand in some cases. Previous
experience in similar duties often provides the best experience. If in doubt, contact your GIW / KSB representative for specific
recommendations.
Commissioning Spares Bearing Assembly

 Gaskets for all equipment  Bearings
 Wet End fasteners  Bearing Assembly Gasket Kit
 Shaft Sleeve w/ gaskets & o-rings  Bearing Lubricant
 Impeller Release Ring assembly
 Impeller Release Ring hardware Shaft Seal
 Mechanical Seal w/ adapter & fasteners  Shaft Sleeve
 Shaft Seal Water Ring
Operational Spares include Commissioning Spares plus  Stuffing Box Packing
 Additional set of gaskets for all equipment  Additional mechanical Seal
 Pump Casing  Seal Plate or Optional Throttle Seal
 Impeller
 Side Liners
47
LCC
12 Troubleshooting
Excessive temperature rise in pump

Pump delivers insufficient flow rate
Excessive leakage at the shaft seal

Vibration during pump operation
Increase in bearing temperature
Excessive discharge pressure
Remedy
Leakage at the pump
Cause For further information consult the GIW Tech Series at:
Motor is overloaded
giwindustries.com
Blocked discharge or suction piping. Remove blockage or open valve.

      WARNING: Pump must not be run with blocked If piping cannot be unblocked immediately, pump must be
piping. Danger of explosion due to heating of shut down without delay.
liquid and overpressure of pump.
System head is higher than expected. Check for unexpected clogging, collapsed line or partially
closed valve.
 
Check system calculations. Adjustment may be needed to
system design and/or pump operating conditions.*
Low flow operation. Increase flowrate. In general, operation below 30% of best
  
efficiency flowrate is not recommended.
System head is lower than expected, leading to Adjustment may be needed to system design and/or pump
 
excessive flowrate. operating conditions.*
   Pump and piping are not completely vented or primed. Vent and / or prime.
Excess air entrained in liquid. Improve sump design and venting to prevent air from
  reaching pump. Consider a froth pump design if air cannot
be avoided.
Partial clogging of impeller. Remove blockage. Be aware that blockage may drain back
   
into sump after shutdown.
Resonance vibrations in the piping. Check pipeline connections and pump mounting.
   If required, reduce the distances between, or otherwise
modify pipe supports.
Insufficient suction head (NPSH available ) Check sump level. Raise if necessary.
Fully open any valves in the suction line.
   
Check suction line friction loss calculations. Alter design if
necessary.*
Density or viscosity of the fluid pumped is higher than Adjustment may be needed to system design and/or pump

expected. operating conditions.*
  Speed is too high. Reduce the speed.
Worn parts. Check for worn parts. Replace as needed.
  
Loose bolts, seals or gaskets. Tighten the bolts and/or fit new seals and gaskets if needed.
Incorrect packing material or adjustment or… Correct adjustment. Replace parts as needed.

Incorrect seal water pressure (too high or low). (See GIW Tech Article on this subject.)
   The unit is misaligned. Check the coupling. Re-align if required.
Bearing failure. Replace bearings. Check lubricant for contamination.
  Inspect and repair bearing seals as needed.
Contact a GIW service center for factory rebuild services.
Insufficient or excessive quantity of lubricant or Correct according to maintenance manual

unsuitable lubricant. recommendations.
Insulating or hot ambient conditions Remove insulation and/or dirt from bearing assembly.

Improve ventilation around pump.
 Operating voltage is too low. Increase the voltage.
* Contact your GIW/KSB representative for further advice.
48
LCC
13 Supplements
Supplements provide additional information for optional equipment. These options may not be available for your pump.
See your Bill of Materials for options that were included with your pump.
13.1 Duo Cone Seals
Seal rings, rubber torics and housings must be completely clean and free of
any oil or dirt. Use a lint free cloth with a solvent that evaporates quickly and
leaves no residue. It must be compatible with rubber toric rings. Isopropyl
Alcohol or other mild cleaner will work. Follow all safety guidelines for use
according to the solvent Material Safety Data Sheet. Check the rubber toric
for surface defects and inspect the entire metal seal face for dirt or marks. Do
not place the polished seal ring face on any surface
Gently stretch the toric over the metal seal rings until it seats in the radius.
Verify that the toric is not twisted by inspecting the mold flash line on the
outside diameter. Eliminate any irregularity by gently pulling a section of the
toric radially off the ring and letting it snap back. Twisted torics will cause
nonuniform face load, resulting in leakage and bearing contamination.
Place the housing end cover and seal holder on a flat, clean surface. Verify that the grooves are clean
and free from burrs or sharp edges. Using the correct Seal Installation Tool, locate the machined ridge
in the tool over the toric and clamp together. Align the parts squarely with the groove and carefully
snap the seal assembly into place using a rapid, even push. Isopropyl alcohol can be used as a
lubricant. Allow time for the assembly lube to evaporate.
49
LCC
Apply a very thin film of pure Molybdenum Disulfide lubricant or light oil to the seal faces just prior to
final assembly. This will lubricate the seals during initial start up. Do not to get any lube on the rubber
toric rings. Be sure there is no debris on either of the seal faces, since even a small piece of lint can
hold the seal faces apart and cause leakage or damage to the sealing surfaces.
Final assembly is detailed on the Bearing Housing Assembly drawing. Bolt the end covers in
place and install the two (2) studs and nuts for the installation tool. Verify that there are no
burrs or sharp edges on the shaft that could damage the o-ring. Coat the long set screws with
anti-seize and thread them into the tapped holes until the points are 1/8” (3mm) from the inside
bore. Install the o-ring in the Seal Holder. Coat the ID of the holder with RTV silicone sealant,
including the o-ring and set screw holes. Place a small bead of silicone around the shaft
diameter to help the o-ring slide. Use extra care at the shaft keyway. Place the gap spacer
over the shaft and carefully slide the holder until it contacts the spacer. Lower the installation
tool over the shaft and tighten the nuts ¼ to ½ turn past hand tight against the tool.
The gap spacer should not move and the holder should contact it evenly on all sides. Tighten the set screws in a crisscross
pattern. Remove the installation tool and gap spacer, and then retorque the set screws. Coat the lock screws with anti-seize
and tighten them in the tapped holes. Fill the tapped holes flush to the top with silicone to protect the set screws. This will
make removal easier for future maintenance. Rotate the shaft by hand and check for smooth operation. Verify that the holders
are square to the end cover. The metal seal rings may appear cocked slightly relative to the holders. This is not a problem, the
rings will run true when the pump starts.
After the assembly is complete, remove one of the pipe plugs from the bearing housing. Install an air line fitting and slowly
pressurize the unit with dry shop air to 10-15 psi or 1 bar. Check all joints and the Duo-Cone seals for leaks by spraying with a
soapy water solution. Do NOT exceed 15 psi, as this could cause the torics to extrude from the seal grooves. If this occurs,
disassemble the unit and reinstall the toric. Release the air pressure, replace the pipe plug and prepare the unit for shipping or
installation on the pump pedestal.
Units being returned to service must be completely filled with oil. Remove the top filler plug and add oil. If the unit will remain
empty during pump installation, be sure it is clearly indicated to ADD OIL prior to start up on both the pump and the control
panel. After the day tank is connected, fill the hoses and tank. Allow time for the oil to displace the air in the lines. Mark the oil
level in the tank for reference. Note that a single hose system or colder temperatures will require time to bleed all the air from
the system. The level should equalize after the pump has been operating for an hour or two. At this point, fill the tank to the
correct operating level.
Underwater Bearing
Shaft Size Assembly Oil Quantity
liters (quarts)
35 mm 1.5 (1.5)
50 mm 4.0 (4.0)
70 mm 9.0 (9.5)
100 mm 18 (19)
125 mm 35 (36)
4–7/16” 18 (19)
5–7/16” 41 (43)
6–7/16” 73 (77)
7–3/16” 88 (93)
9” 131 (138)
10–1/4” 170 (180)
11–1/2” 284 (300)
Approximate Values
50
LCC
NOTES
51
LCC
General Drawing with List of Components
Pump assembly, bill of material and other drawings or special instructions relevant to each order will be attached to the back of
this manual.
52
Date 11.06.2018
DnD 150 DC13
Rev 00
Pump DnD 150
P a g e | 66
DnD-04
ENGINE MANUAL
Important information
Serious risk of injury
When working on the engine, for example when adjusting drive belts and the clutch, or when changing the
oil, it is important not to start the engine. The engine could be damaged, but more importantly there is a
serious risk of injury.
For this reason, always secure the starting device or disconnect a battery cable before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
WARNING!
This warning symbol and text can be found next to those maintenance items where it is particularly impor-
tant to bear in mind the risk of injury.
Operator's manual
DC13
PDE
Industrial engine
en-GB 2 428 360
Issue 3.0
Start-up Report – Warranty

The warranty starts when the start-up report has been filled in and sent to Scania. The normal warranty pe-
riod is 1 year, but other conditions can apply.
Fill in the particulars in the start-up report below as well. This can make things easier if you need to contact
a workshop, for example.
Engine serial number

Date of entry into service
User's name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine data plate.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Preparing the engine for storage . . . . . . . . . . .55
Environment and safety . . . . . . . . . . . . . . . . . . 4 Handling the engine . . . . . . . . . . . . . . . . . . . .55
Environmental responsibility . . . . . . . . . . . . . 4 Preservative coolant . . . . . . . . . . . . . . . . . . . .55
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Preservative fuel. . . . . . . . . . . . . . . . . . . . . . .55
Warnings and advisories . . . . . . . . . . . . . . . . . 5 Preservative oil. . . . . . . . . . . . . . . . . . . . . . . .55
Certification . . . . . . . . . . . . . . . . . . . . . . . . . 10 Preparations for storage . . . . . . . . . . . . . . . . .56
Engine data plate . . . . . . . . . . . . . . . . . . . . . . . 11 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . .58
Component identification . . . . . . . . . . . . . . . . 12 General data . . . . . . . . . . . . . . . . . . . . . . . . . .58
Starting and running . . . . . . . . . . . . . . . . . . . . 13 Lubrication system . . . . . . . . . . . . . . . . . . . . .58
Checks before running . . . . . . . . . . . . . . . . . 13 Injection system . . . . . . . . . . . . . . . . . . . . . . .59
Starting the engine . . . . . . . . . . . . . . . . . . . . 13 Cooling system. . . . . . . . . . . . . . . . . . . . . . . .59
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Intake system . . . . . . . . . . . . . . . . . . . . . . . . .59
Engine shutdown. . . . . . . . . . . . . . . . . . . . . . 16 Electrical system . . . . . . . . . . . . . . . . . . . . . .59
Checks after running . . . . . . . . . . . . . . . . . . . 16 Scania Assistance . . . . . . . . . . . . . . . . . . . . . . .60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engines with few hours of operation . . . . . . 18
Maintenance intervals . . . . . . . . . . . . . . . . . . 19
Lubrication system . . . . . . . . . . . . . . . . . . . . . 20
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Checking oil level . . . . . . . . . . . . . . . . . . . . . 21
Changing the oil . . . . . . . . . . . . . . . . . . . . . . 22
Labels for top-up engine oil grade . . . . . . . . 23
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cleaning the centrifugal oil cleaner . . . . . . . 24
Operational testing . . . . . . . . . . . . . . . . . . . . 29
Renewing the oil filter. . . . . . . . . . . . . . . . . . 30
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 31
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Checking coolant level . . . . . . . . . . . . . . . . . 34
Checking antifreeze and corrosion inhibitor . 34
Antifreeze and corrosion inhibitor . . . . . . . . 35
Changing coolant . . . . . . . . . . . . . . . . . . . . . 36
Cleaning the cooling system . . . . . . . . . . . . . 38
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Reading the vacuum indicator. . . . . . . . . . . . 40
Renewing the filter element . . . . . . . . . . . . . 40
Renewing the safety cartridge. . . . . . . . . . . . 41
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking fuel level . . . . . . . . . . . . . . . . . . . . 42
Renewing the fuel filter. . . . . . . . . . . . . . . . . 43
Renewing the water separating fuel filter . . . 44
Bleeding the fuel system . . . . . . . . . . . . . . . . 45
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking the drive belt . . . . . . . . . . . . . . . . . 46
Checking for leaks . . . . . . . . . . . . . . . . . . . . 47
Checking and adjusting the valve clearance . 48
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Composition of the fuel. . . . . . . . . . . . . . . . . 53
Sulphur content of fuel . . . . . . . . . . . . . . . . . 53
Temperature dependency of the fuel. . . . . . . 53
Biodiesel (FAME). . . . . . . . . . . . . . . . . . . . . 54
Use of fuel oil in stand-by generator sets . . . 54
OPM 210 en-GB 2

© Scania CV AB 2016, Sweden
Introduction
Introduction
This Operator's manual describes the operation
and maintenance of Scania industrial engines.
The engines are direct-injection, liquid-cooled,
four-stroke turbocharged diesel engines.
The engines are available with different output
and engine speed settings. Engine power for the
engine ordered is indicated on a plate located on
the engine control unit.
Note:
Only standard components are described in the
operator's manual. Information about special
equipment is contained in instructions from the
various manufacturers.
To ensure the maximum performance and the

longest service life for the engine remember the
following:
• Read through the Operator's manual before
starting to use the engine. Even regular users
of Scania engines will get new information
from the Operator's manual.
• Always follow the maintenance instructions.
• Read the section on safety carefully.
• Get to know your engine so that you know
what it can do and how it works.
• Always contact an authorised Scania work-
shop.
The information in this manual was correct at the

time of going to press. Scania reserves the right
to make alterations without prior notice.
Note:
Always use Scania spare parts for maintenance
and repair.
OPM 210 en-GB 3

Environment and safety
Environment and safety Different types of advisory

Warning!
Environmental responsibility All advisories preceded by Warning! are very
Scania develops and produces engines that are as important. They warn of serious faults and incor-
environmentally-friendly as possible. Scania has rect operation that could lead to personal injury.
made major investments in the reduction of Example:
harmful exhaust emissions in order to fulfil the
environmental requirements in force in almost
every market. WARNING!
At the same time, we have been able to maintain Block the starting device when working on the
a high level of performance and operating econ- engine. If the engine starts unexpectedly, there is
omy for Scania Industrial and Marine Engines. a serious risk of injury.
To maintain these throughout the entire service
life of the engine, it is important for the user to
follow the instructions on running, maintenance
and fuel and lubricating oil as outlined in the Op-
erator's manual. Important!
Other green initiatives taken include ensuring Advisories preceded by Important! warn of
that, following maintenance and repair, waste faults and incorrect operation that could lead to
that is harmful to the environment (for example equipment being damaged. Example:
oil, fuel, coolant, filters and batteries) is disposed
of accordance with the applicable environmental IMPORTANT!
requirements.
For Scania to guarantee that the engine corre-
sponds to its certified configuration, and take re-
Safety sponsibility for any damage and injuries that
occur, maintenance must be carried out as above.
The following pages contain a summary of the
safety precautions to be complied with when op-
erating and maintaining Scania engines. The
equivalent text can also be found under the rele-
vant maintenance item.
To prevent damage to the engine and to ensure
that it runs optimally, follow the instructions in
the warnings and advisories.
If the instructions are not followed, the warranty
can cease to apply.
OPM 210 en-GB 4

Note: Safety precautions for running the

Advisories preceded by Note: refer to informa- engine
tion important to ensure the best possible opera- Daily maintenance
tion and functionality. Example:
Always carry out a visual inspection of the en-
Note: gine and engine compartment before starting the
Always use genuine Scania parts during mainte- engine or when the engine has been switched off
nance and repair so as to keep your engine in the after operation.
best possible working order. This inspection should be done to detect fuel, oil
or coolant leaks, or anything else that may re-
quire corrective action.
Environment
This Operator’s manual contains specially high- Fuel
lighted text with instructions to help protect the Use only fuel recommended in the Workshop
environment during maintenance. Example: Manual.
Environment WARNING!
Use a container to avoid spillage. The wrong fuel grade can cause breakdowns or
stoppages by causing the injection system to
malfunction. This can cause damage to the en-
gine and, possibly, personal injury.
Warnings and advisories
Smoking
Refuelling
WARNING! Never overfill the fuel tank as the fuel needs
space to expand. Also ensure that the filler cap is
Smoking is prohibited properly closed.
• in the vicinity of flammable or explosive ma-

terial, e.g. fuel, oils, batteries, chemicals WARNING!
• when refuelling and in the vicinity of the fill-
During refuelling there is a risk of fire and explo-
ing station
sion. The engine must be switched off and smok-
• when working on the fuel system ing is prohibited.
OPM 210 en-GB 5

Hazardous gases Running
WARNING! WARNING!
Only start the engine in a well ventilated area. The engine must not be run in environments
The exhaust gases contain carbon monoxide and where there is a risk of explosion, as all of the
nitrogen oxides, which are toxic. electrical or mechanical components can gener-
ate sparks.
If it is run in an enclosed space, there should be
an effective device to extract exhaust gases and Approaching a running engine always poses a
crankcase gases. safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts such as the
fan and cause injury. For personal safety all ro-
tating parts and hot surfaces must be fitted with
guards.
Starter lock
IMPORTANT!
If the control panel is not fitted with a starter Safety precautions for handling ma-
terials
lock, the engine compartment should be locked
to prevent unauthorised personnel from starting Fuel and lubricating oil
the engine. Alternatively, a lockable master
switch or battery master switch can be used.
WARNING!
All fuels and lubricants as well as many chemi-

cals are flammable. Always follow the instruc-
Starter gas tions on the relevant packaging.
The work must be carried out on a cold engine.
WARNING!
Fuel leaks and spillage on hot surfaces can cause
fire.
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in Store used rags and other flammable materials
the intake manifold and possible injury. safely so as to avoid spontaneous combustion.
OPM 210 en-GB 6

Batteries Safety precautions for maintenance

and repair
WARNING! Switch off the engine
Always switch off the engine before carrying out
The batteries contain and form oxyhydrogen gas,
maintenance and repair work, unless otherwise
particularly during charging. Oxyhydrogen gas
indicated.
is flammable and highly explosive.
Make it impossible to start the engine: Remove
There must be no smoking, naked flames or
any starter key, or cut the power using the main
sparks near the batteries or the battery compart-
power switch or battery master switch and lock
ment. Incorrect connection of a battery cable or
them.
jump lead can cause a spark, which can cause the
battery to explode. Fix a warning plate somewhere appropriate,
showing that work is being carried out on the en-
gine.
Chemicals WARNING!
WARNING! Working with a running engine always poses a

safety risk. Parts of the body, clothes or dropped
Most chemicals such as glycol, anti-corrosive tools can get caught in rotating parts and cause
agents, preservative oils and degreasing agents, injury.
are hazardous to health.
Some chemicals, such as preservative oil, are
also flammable.
Hot surfaces and fluids
Always follow the safety precautions on the rel-
evant packaging.
WARNING!
Store chemicals and other materials which are
hazardous to health in approved containers, There is always a risk of sustaining burns when
marking them clearly and storing them where an engine is hot. Particularly hot parts are engine
they are inaccessible to unauthorised persons. manifolds, turbochargers, oil sumps, hot coolant
and oil in pipes and hoses.
Environment
Always hand in leftover and used chemicals to

an authorised waste disposal contractor.
OPM 210 en-GB 7

Lifting the engine Electrical system

Always use the engine lifting eyes. Always The engine must be switched off and the power
check that lifting accessories are in good condi- disconnected using the master switch or battery
tion and are designed to lift the weight. master switch before working on the electrical
system. External power supplies to extra equip-
Optional equipment on the engine can change ment on the engine must also be disconnected.
the centre of gravity. This means that it may be
necessary to use additional lifting devices to bal-
ance the engine correctly and lift it safely. IMPORTANT!
Always use Scania spare parts for the fuel and

WARNING! electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
Never work underneath a suspended engine!
Electric welding
Batteries
IMPORTANT!
WARNING!
When carrying out welding work on and near the
The batteries contain highly corrosive sulphuric engine, disconnect the battery and alternator
acid. Take care to protect your eyes, skin and leads. Pull out the multi-pin connector for the en-
clothes when charging or handling batteries. gine control unit as well.
Wear protective gloves and goggles.
Connect the welding clamp close to the compo-
If sulphuric acid comes in contact with the skin: nent to be welded. The welding clamp must not
Wash with soap and plenty of water. If it gets in be connected to the engine, or so that the current
your eyes: Rinse immediately with plenty of wa- can cross a bearing.
ter and seek medical attention.
When welding is finished:
1. Connect the alternator and control unit ca-
bles first.
Environment
2. Then connect the batteries.
Always hand in used batteries to an authorised
waste disposal contractor.
OPM 210 en-GB 8

Lubrication system Fuel system
WARNING! WARNING!
Hot oil can cause burns and skin irritation. Wear Always wear protective goggles when testing in-
protective gloves and goggles when changing jectors. Fuel escaping at high pressure can pene-
hot oil. trate tissues and cause serious injury.
Make sure that there is no pressure in the lubri- Always use Scania spare parts for the fuel and
cation system before starting work on it. electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
The oil filler cap must always be in place when
starting and running the engine to prevent oil be-
ing ejected.
Before starting
Environment Ensure that all guards are in place before starting
the engine. Ensure that no tools or other objects
Always hand in used oil to an authorised waste have been left on the engine.
disposal contractor.
WARNING!
The air filter must be fitted before starting the en-

Cooling system gine. Otherwise there is a risk of objects being
sucked into the compressor impeller or of injury
if you come into contact with the air filter.
WARNING!
Never open the coolant filler cap when the en-

gine is hot. Hot coolant and steam may spray out
and cause burns.
If the cap has to be opened do it slowly and care-
fully to release the pressure before removing the
cap. Wear gloves as the coolant is still very hot.
Environment
Always hand in used coolant to an authorised

waste disposal contractor.
OPM 210 en-GB 9

Certification
An emissions certified engine fulfils the emis-
sions requirements for a particular range of ap-
plication.
On each emissions certified engine there is a la-
bel which shows which requirements the engine
fulfils. Scania guarantees that each such engine
fulfils the emissions requirements for the range
of application for which it is certified.
The following are required for the certified en-
gine to fulfil the emissions requirements once it
has been taken into service:
• Maintenance is to be carried out in accord-
ance with the instructions in this Operator's
manual.
• Maintenance and repairs of injection equip-
ment are to be carried out by an authorised
Scania workshop.
• The engine may only be modified with equip-
ment that has been approved by Scania.
• Seals may be broken and setting data edited
only once approval has been granted by Sca-
nia. Modifications may be made by author-
ised personnel only.
• Modifications affecting the exhaust and in-
take systems must be approved by Scania.
Otherwise, the instructions in the Operator's

manual for the running and maintenance of the
engine shall apply. The safety precautions on the
following pages must be observed.
IMPORTANT!
For Scania to guarantee that the engine corre-

sponds to its certified configuration, and take re-
sponsibility for any damage and injuries that
occur, maintenance must be carried out as above.
OPM 210 en-GB 10

Engine data plate
Engine data plate

The engine data plate indicates, in the form of a
code, the engine type, its size and applications. It
also indicates the engine type power range and
operating speed. The engine EU type approval
for exhaust emissions is indicated under Output,
where applicable.
The engine power is stated on a plate which is lo-
cated on the engine control unit.
The engine serial number is stamped onto the top
of the cylinder block at the front right.
Example: DC13 074A

DC Supercharged diesel engine with air-cooled charge air cooler.
13 Displacement in whole dm3.
074 Performance and certification code. The code indicates, together
with the application code, the normal gross engine output.
A Code for application. A means for general industrial use.
Made b y
Type DC13 074A

Engine No 1234567
Output . 257-368 kW 2100 r pm .
Output . kW r pm .
350 594
Example of an engine data plate
OPM 210 en-GB 11

Component identification
Component identification
1 2 3
9
10
4
5 11
7 15
318 018
8
13 12
318 017
14
The illustrations show a normal version of a DC13 engine. The engine ordered may have different equip-
ment.
Note:
The water separating prefilter for the fuel is lo-
cated between the fuel tank and engine.
1. Turbocharger 9. Engine data plate

2. Oil cooler 10. Fuel filter
3. Oil filler 11. Fuel pump with hand pump
4. Engine serial number on the cylinder 12. Starter motor
block 13. Oil dipstick
5. Oil filter 14. Oil plug
6. Coolant pump 15. Engine control unit
7. Valve for draining coolant
8. Centrifugal oil cleaner
OPM 210 en-GB 12

Starting and running
Starting and running If the fuel tank has been run dry or if the engine
has not been used for a long time, bleed the fuel
Note: system.
When the engine is started for the first time, car-
ry out the maintenance items listed under First WARNING!
start in the maintenance schedule. See the Main-
tenance section. Never use starter gas or similar agents to help
start the engine. An explosion may occur in the
intake manifold with a risk of personal injury.
Always check the following before running:
Only start the engine in a well ventilated area.
• oil level
When the engine is run in an enclosed space,
• coolant there must be effective devices to extract exhaust
• fuel level gases and crankcase gases.
• electrolyte level in batteries
• state of charge of the batteries
• condition of the drive belt. IMPORTANT!
Checks before running

The starter motor must only be cranked twice for
30 seconds at a time. After that, it must rest for at
Carry out daily maintenance as described in the least 5 minutes before the next attempt to start it.
maintenance schedule prior to operation. See the
Maintenance section.
Starting at low temperatures and at
high altitudes
WARNING!
Take the local environmental requirements into
account. Use a fuel heater and engine heater to
Block the starting device when working on the avoid starting problems and white smoke.
engine. If the engine starts unexpectedly, there is
a serious risk of injury. Scania recommends that an engine heater should
be used if the engine will be used at temperatures
below -10°C or at an altitude of more than 2,000
Starting the engine metres.
A low engine speed and a moderate load on a
For environmental reasons the Scania engine has cold engine limits white smoke, gives better
been developed to be started with a low fuel feed. combustion and warms up the engine more
Using unnecessarily large amounts of fuel when quickly than warming it up with no load.
starting the engine always results in emissions of
unburnt fuel. Avoid running it longer than necessary at idling
speed.
1. Open the fuel cock if fitted.
2. Disengage the engine.
3. If the engine has a battery master switch:
Connect the power using the battery master
switch.
4. Start the engine.
OPM 210 en-GB 13

Running Throttle opening fault, but the idling switch is

working:
Check instruments and warning lamps at regular
intervals. • The throttle opening value can be increased
slowly between 0 and 50% by using the idling
switch.
Engine speed range CAN fault:
• The engine is switched off if the shutdown
600-750 rpm Low idling. Engine idling is function is activated.
controlled by the engine
management system.
Low idling up to Engine operating speed
2,100 rpm range. Controlled by the Driving at high altitude
engine management system. When driving at high altitudes engine power is
2,100-2,600 rpm Unsuitable operating speed, reduced automatically due to the lower oxygen
but a slightly higher engine content in the air. It is then not possible to run the
speed than the normal maxi- engine at maximum power.
mum operating speed may
occur when load is low or Note:
negative. Driving at a higher height than 4,000 metres
2,600-3,000 rpm Prohibited engine speed. above sea level is only permitted if it has first
been approved by Scania.
Limp home mode

If there is a fault in the normal throttle opening or
if CAN communication is interrupted, the fol-
lowing emergency operation option is provided:
A CAN fault or throttle opening fault in an all-
speed engine (both signal and idling switch):
• The throttle opening value is 0% and the en-
gine is running at normal idling speed.
• The throttle opening value is 0% and the en-
gine is running at raised idling speed (750
rpm) if this function is activated.
OPM 210 en-GB 14

Coolant temperature Oil pressure

Normal coolant temperature during operation is Information about the normal oil pressure and
80-90°C/176-194°F. lowest permitted oil pressure is contained in the
section headed Technical Data.
Alarm levels are set in the engine control unit.
The default setting for the lowest and highest The engine management system has the follow-
limit values for high coolant temperature are ing alarm levels:
95°C/203°F and 105°C/221°F respectively.
• At an engine speed below 1,000 rpm and an
The high coolant temperature alarm has the fol- oil pressure below 0.7 bar/10.2 psi.
lowing functions: • At an engine speed above 1,000 rpm and an
• Alarm only. oil pressure below 2.5 bar/36.3 psi for longer
than 3 seconds.
• Alarm and torque reduction at the lowest lim-
it value. The incorrect oil pressure alarm has the follow-
• Alarm at the lowest limit value and engine ing functions:
shutdown at the highest limit value.
• Alarm only.
• Alarm, torque reduction at the lowest limit
• Alarm and torque reduction by 30%.
value and engine shutdown at the highest lim-
it value. • Alarm and engine shutdown.
• Alarm at the lowest limit value and engine • Alarm and engine shutdown override control.
shutdown at the highest limit value with the
possibility of engine shutdown override con- Note:
trol. High oil pressure (above 6 bar/87 psi) is normal
• Alarm, torque reduction at the lowest limit if the engine is cold when started
value and engine shutdown at the highest lim-
it value, with the possibility of engine shut-
down override control. Charging indicator lamp
If run for extended periods under an extremely If the lamp comes on during operation:
light load, the engine may have difficulty in • Check and adjust the alternator drive belts as
maintaining the coolant temperature. At an in- described under the corresponding mainte-
creased load the coolant temperature rises to the nance item. See the Maintenance section.
normal value.
If the charging indicator lamp is still on, this
could be due to an alternator fault or a fault in the
IMPORTANT!
electrical system.
An excessively high coolant temperature can Belt transmission
damage the engine.
When the belt transmission is new, it may make
a squeaking noise when running. The noise is
normal and disappears after 50-100 hours of op-
eration.
The noise does not affect the service life of the
belt transmission.
OPM 210 en-GB 15

Engine shutdown Checks after running

1. Run the engine without a load for a few min-
utes if it has been run continuously with a WARNING!
heavy load.
2. Switch off the engine. Block the starting device when working on the
Note: a serious risk of injury.
The battery voltage must remain on for a few There is always a risk of sustaining burns when
seconds after the 15 voltage is switched off so an engine is hot. Particularly hot parts are turbo-
that the control units can store the values and chargers, oil sumps, hot coolant and oil in pipes
switch to standby mode. and hoses.
10 prohibited engine shutdowns will cause a
torque reduction (70% of fuel quantity). Reset 1. Check that the power supply has been cut.
the engine by switching it off correctly once.
2. Fill the fuel tank. Make sure that the filler
cap and the area round the filler opening are
clean to avoid contamination of the fuel.
IMPORTANT! 3. If there is a risk of freezing, the cooling sys-
tem must contain enough glycol.
There is risk of post boiling and of damage to the
4. If the temperature is below 0°C/32°F: Pre-
turbocharger if the engine is switched off with-
pare for the next start by connecting the en-
out cooling.
gine heater (if fitted).
The power must not be switched off before the
engine has stopped.
IMPORTANT!
Check the coolant level following the first start.

Top up if necessary.
OPM 210 en-GB 16

Maintenance
Maintenance
IMPORTANT!
The maintenance programme covers a number of
points that are divided into the following sec- On delivery a Scania engine is optimised for its
tions: application. However, regular maintenance is
necessary to:
• Lubrication system
• Cooling system • prevent unplanned stops
• Air cleaner • extend the service life of the engine
• Miscellaneous • maximise the long-term emission perfor-
mance of the engine
• give the best possible operating economy.
WARNING!
Block the starting device when working on the

a serious risk of injury.
The maintenance programme includes the fol-

lowing:
• S maintenance: Minimum basic maintenance.
• M maintenance: More extensive mainte-
nance.
• L maintenance: Includes nearly all mainte-
nance items.
• XL maintenance: Includes all maintenance
items.
During a period, the sequence is S-M-S-L-S-M-

S-L-S-M-S-XL.
XL
L L
M M M
S S S S S S
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
313 153
OPM 210 en-GB 17

Maintenance
Engines with few hours of op-

eration
IMPORTANT!
On engines with few hours of operation, mainte-

nance must be carried out annually or every 5
years.
Stand-by generator sets and the like that are not

used regularly should be test run and checked in
accordance with the manufacturer's instructions.
The following maintenance items must be car-
ried out once the engine has been warmed up to
operating temperature.
1. Checking oil level.
2. Checking coolant level.
3. Checking the vacuum indicator.
4. Checking fuel level.
5. Check for engine leaks.
OPM 210 en-GB 18

Maintenance
Maintenance intervals
Daily First time at Interval (hours) At least

first start 500 500 1,000 2,000 6,000 annu- every
R S M L XL ally 5
years
Lubrication system
Checking oil level X X
Changing the oil X X X X X X
Cleaning the centrifugal oil
X X X X X X
cleaner
Renewing the oil filter X X X X X X
Cooling system
Checking coolant level X X X X X X X
Checking antifreeze and corro-
X X X X
sion inhibitor
Cleaning the cooling system and
X X
changing coolant
Air cleaner
Reading the vacuum indicator X X X X X X
Renewing the filter element X X X
Renewing the safety cartridge X X X
Fuel system
Checking fuel level X X
Renewing the fuel filter X X X X
Miscellaneous
Checking the drive belt X X X X X
Checking for leaks X X X X X
Checking and adjusting the valve
X X X
clearance
OPM 210 en-GB 19

Lubrication system
Lubrication system
Oil grade
Scania LDF stands for the Scania Long Drain
Field test standard. Scania LDF oils have been
carefully selected after extensive testing. The ap-
proval is only granted to the highest quality en-
gine oils available on the market.
Recommended oil
Scania Oil LDF
Scania Oil LDF-2
Scania Oil LDF-3
Scania Oil E7
The engine oil must fulfil the following quality

requirements:
• ACEA E5/API CI-4
• ACEA E7/API CI-4 +
• For engines not run on low-sulphur fuel, the
TBN (Total Base Number) should be at least
12 (ASTM D2896).
• Oils with a low ash content (ACEA E9/API
CJ4) are not recommended.
Check with your oil supplier that the oil meets

these requirements.
If the engine is used in areas of the world where
lubricating oil with ACEA or API classification
is not available, the oil grade must be measured
in actual operation. In this case contact the near-
est Scania workshop.
For operation at extremely low outdoor tempera-
tures: Consult your nearest Scania representative
on how to avoid starting difficulties.
Viscosity class Outdoor temperature

SAE 20W-30 -15°C (5°F) - +30°C (86°F)
SAE 30 -10°C (14°F) - +30°C (86°F)
SAE 40 -5°C (23°F) - > +45°C (113°F)
SAE 50 0°C (32°F) - > +45°C (113°F)
SAE 5W-30 < -40°C (-40°F) - +30°C (86°F)
SAE 10W-30 -25°C (-13°F) - +30°C (86°F)
SAE 15W-40 -20°C (-4°F) - > +45°C (113°F)
OPM 210 en-GB 20

Lubrication system
Oil analysis
To be able to extend the oil change intervals us-
ing an oil analysis, Scania LDF-2 and LDF-3 oils
must be used.
Oil companies can offer analysis of the engine
oil.
The following conditions must remain fulfilled
when the oil is changed.
• Viscosity at 100°C (212°F): max. ±20% of
original value of the fresh oil.
• TBN (in accordance with ASTM D4739): >
3.5
• TBN (in accordance with ASTM D4739): >
TAN (in accordance with ASTM D664)
• Soot (DIN 51452): < 3%
Such analysis measures the oil's TBN (Total

Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quanti-
ty of particles and soot in the oil.
The result of a series of analyses is used as the
basis for establishing a suitable oil change inter-
val.
If the conditions are changed, a new oil analysis
programme must be carried out to establish new
change intervals.
Checking oil level 2
Checking the oil level with the engine

switched off
1
Note:
Leave the engine off for at least 1 minute before
checking the oil level.
1. Remove the oil dipstick (1) and check the oil

312 506
level. The correct level is between the mini-

mum and maximum marks on the oil dip-
stick.
2. Top up with more oil (2) when the oil level is
at or below the lower mark.
Information on the correct oil type is found under

the heading Oil grade.
OPM 210 en-GB 21

Lubrication system
Changing the oil
WARNING!
Hot oil can cause burns and skin irritation. Wear

protective gloves and goggles when changing
hot oil. Make sure that there is no pressure in the
lubrication system before starting work on it.
The oil filler cap must always be in place when
starting and running the engine to prevent oil be-
ing ejected.
Note:
Renew the oil filter and clean the centrifugal oil
cleaner when changing oil.
314 603
Change oil more often if the engine is subjected
to particularly demanding operation, such as a
dusty environment, or if deposits in the centrifu- Max. 45 litres (11.9 US gallons).
gal oil cleaner are thicker than 28 mm (1.1 in).
Min. 39 litres (10.3 US gallons).
Environment
Use a container to avoid spillage. Used oil must

be disposed of as specified in national and inter-
national law.
1. Unscrew the oil plug and drain the oil when 314 602
the engine is hot. In certain engines the oil is
pumped out by means of a bilge pump.
When draining with the valve, the oil should Max. 34 litres (9 US gallons).
be hot. Alternatively, use a pump. This so Min. 28 litres (7.4 US gallons).
that draining occurs more quickly.
2. Clean the magnet on the oil plug.
3. Refit the oil plug.
30°
4. Top up with oil.
30°
5. Check the level on the oil dipstick.
30° 30°
Maximum angles of inclination during opera-
tion
25°
Maximum permissible angles during operation 25°
vary, depending on the type of oil sump; see il- 30° 30°
lustration.
35°
35°
343 839
45° 45°
OPM 210 en-GB 22

Lubrication system
Labels for top-up engine oil

grade
When changing oil it is important to use the cor-
rect engine oil grade.
The oil filler cap must be clearly marked with a
label showing the top-up oil grade.
If the label is missing or if the engine oil grade is

changed, a new label must be fitted.
336 492
Filling label in the cylinder block.
353 114
Filling label in the rocker cover.
Parts
Oil grade Colour Part No. Part No.

Filling in the cylinder Filling in the rocker cover
block
Scania LDF-2 Blue 2 132 424 2 296 064
Scania LDF-3 Red 2 132 426 2 296 066
Scania LDF Grey 2 269 345 2 296 071
ACEA E7 White 2 132 425 2 296 065
Scania Low Ash Green 2 132 427 2 296 067
Scania Bioethanol Black 2 132 428 2 296 068
Scania BEO-2 Orange 2 258 841 2 296 070
ACEA E9 - 2 132 429 2 296 069
OPM 210 en-GB 23

Lubrication system
Cleaning the centrifugal oil

cleaner
Designation Illustration
Torque wrench 2-20 Nm with exchangeable ratchet head
340 130
When cleaning the centrifugal oil cleaner there
will be some dirt deposits in the rotor cover. If
this is the case, this indicates that the rotor is
working. If it is clean and not working, the cause
must be established immediately.
If the dirt deposit exceeds 28 mm at the recom-
mended intervals, the rotor cover should be
cleaned more often.
WARNING!
The oil may be hot. Carefully remove the cover x 1.5

from the centrifugal oil cleaner.
1. Clean the cover. Unscrew the nut securing

the outer cover.
2. Let the oil run out from the rotor.
3. Lift out the rotor. Wipe off the outside. Undo
the rotor nut and unscrew it about 1.5 turns to
133 315
protect the bearing.
Note:
Take care not to damage the rotor shaft.
OPM 210 en-GB 24

Lubrication system
4. If the rotor nut is difficult to get loose, turn

the rotor upside down and fasten the rotor nut
in a vice. Turn the rotor anti-clockwise
1.5 turns by hand or use an M20 nut, see il- M20
lustration.
IMPORTANT!
The rotor must not be put in a vice. Never strike x 1.5

the rotor cover. This may cause damage resulting
in imbalance.
133 316
5. Remove the rotor cover by holding the rotor
in both hands and tapping the rotor nut
against the table. Never strike the rotor di-
rectly as this may damage its bearings.
133 317
OPM 210 en-GB 25

Lubrication system
6. Remove the strainer from the rotor cover. If

the strainer is stuck, insert a screwdriver be-
tween the rotor cover and strainer and care-
fully prise them apart.
127 878
7. Remove the paper insert and scrape away
any remaining dirt deposits inside the rotor
cover. If the deposits are thicker than 28 mm,
the centrifugal oil cleaner must be cleaned
more often.
333 044
8. Wash all parts.

9. Inspect the 2 nozzles on the rotor. Ensure that
they are not blocked or damaged. Renew any
damaged nozzles.
10. Check that the bearings are undamaged.
333 037
OPM 210 en-GB 26

Lubrication system
11. Fit a new paper insert on the inside of the ro-

tor cover.
2 3 4
337 178
OPM 210 en-GB 27

Lubrication system
12. Fit the strainer onto the rotor.

13. Fit a new O-ring by sliding it over the strain-
er.
14. Refit the rotor cover. Ensure that the O-ring
is not outside the cover.
15. Tighten the rotor nut by hand.
16. Check that the shaft is not damaged or loose.
127 881
Note:
Take care not to damage the rotor shaft.
17. Refit the rotor and rotate it by hand to make

sure it rotates easily.
127 882
OPM 210 en-GB 28

Lubrication system
18. Fit a new O-ring in the cover. Refit the cover

and tighten the lock nut.
IMPORTANT!
To reduce the risk of oil leakage it is important to

tighten the cover to the correct tightening torque.
From engine serial number 6 841 928:

Tightening torque 20 Nm.
Older engine serial number:
Tightening torque 15 Nm.
Note:
333 043
A torque wrench together with a ratchet head is
suitable for use during maintenance of the cen-
trifugal oil cleaner.
Operational testing
Operational testing need only be carried out if it
is suspected that the centrifugal oil cleaner is not
working properly. For example, if there is an ab-
normally small amount of deposit in the centrif-
ugal oil cleaner in relation to the distance driven.
The rotor rotates very fast and should continue to
turn when the engine has stopped.
1. Run the engine until it is warm.
2. Turn off the engine and listen for the sound
from the rotor. Use your hand to feel if the
333 039
filter housing is vibrating.

3. If the filter housing is not vibrating, disman-
tle and check the centrifugal oil cleaner.
OPM 210 en-GB 29

Lubrication system
Renewing the oil filter

Hexagon socket, 1/2” drive, 36 mm
118 268
IMPORTANT!
Only use a Scania oil filter.
IMPORTANT!
Clean the centrifugal oil cleaner when renewing

the oil filter. Otherwise, the oil filter will be
blocked and resistance in the filter will increase.
If this happens, an overflow valve in the filter re-
tainer opens and lets the oil pass without being
filtered.
1. Unscrew the filter with the socket.
312 503
IMPORTANT!
Do not use an adjustable spanner or other open

tool as there is risk of damaging the filter cover.
2. Lift out the filter housing cover with filter el-

ement. The filter housing will drain automat-
ically once the filter has been removed.
3. Detach the old filter from the cover by hold-
ing the cover and carefully tapping the entire
filter element against something hard. Re-
member that there will be oil splashes.
4. Fit the new filter and tighten the filter cover
to 25 Nm (18 lbf/ft).
312 502
OPM 210 en-GB 30

Cooling system
Cooling system Coolant resistance to cold

The following example shows coolant properties
Coolant with 30 percent by volume of antifreeze and cor-
rosion inhibitor:
WARNING! • Ice slush starts to form at -16°C (3°F).

• At -30°C (-22°F), there is a risk of cooling
Ethylene glycol can be fatal if ingested and can system malfunction.
cause skin irritation and eye damage. • There is no risk of damage by freezing with a
minimum antifreeze and corrosion inhibitor
content of 35 percent by volume.
The coolant recommended by Scania is a mix-
ture of water with antifreeze and corrosion inhib- The chart depicts coolant properties at different
itor (ethylene glycol). The coolant has several percents of antifreeze and corrosion inhibitor
characteristics which are important for the oper- concentration by volume.
ation of the cooling system:
0 10 20 30 40 50 %
• Corrosion inhibitor 0
• Antifreeze -10
• Increases the boiling point -16 1
-20
The coolant should always contain 35-55% by -30
volume of antifreeze and corrosion inhibitor so 3 2
that the coolant properties ensure that the coolant -40
works correctly.
-50
312 505
Note: °C B A
The coolant should be changed when the cooling
system is cleaned: every 6,000 hours or at least Curve A: Ice formation starts (ice slush)
every 5 years. Refer to Changing coolant. Curve B: Damage by freezing occurs
Area 1: Safe area
Area 2: Malfunctions may occur (ice
slush)
Area 3: Risk of damage by freezing
OPM 210 en-GB 31

Cooling system
Antifreeze and corrosion inhibitor con-

centration table
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
1. The total volume of the cooling system is 40
litres in this example.
2. The measured concentration of ethylene gly-
col is 35% by volume (freezing point -21
°C). According to the table there are 14 litres
of ethylene glycol in the cooling system.
3. The required concentration of ethylene gly-
col is 45% by volume (freezing point -30
°C). According to the table, 18 litres of eth-
ylene glycol are required in the cooling sys-
tem.
4. Since there are already 14 litres in the cool-
ing system, 4 litres of ethylene glycol must
be added to the cooling system (18 - 14 = 4
litres).
For calculation Adequate protection against corrosion

Volume of ethylene glycol Cooling system
(%) 20 25 30 35 40 45 50 60 volume (litres)
Ice slush forms (°C) -6 -9 -12 -21 -24 -30 -38 -50
5 6 8 11 12 14 15 18 30
6 8 10 14 16 18 20 24 40
8 10 13 18 20 23 25 30 50
9 12 15 21 24 27 30 36 60
11 14 18 25 28 32 35 42 70
12 16 20 28 32 36 40 48 80
14 18 23 32 36 41 45 54 90
15 20 25 35 40 45 50 60 100
Volume of ethylene glycol (li- 17 22 28 39 44 50 55 66 110
tres) 18 24 30 42 48 54 60 72 120
20 26 33 46 52 59 65 78 130
21 28 35 49 56 63 70 84 140
23 30 38 53 60 68 75 90 150
24 32 40 56 64 72 80 96 160
26 34 43 60 68 77 85 102 170
27 36 45 63 72 81 90 108 180
29 38 48 67 76 86 95 114 190
30 40 50 70 80 90 100 120 200
OPM 210 en-GB 32

Cooling system
Antifreeze and corrosion inhibitor con-

centration table
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
1. The total volume of the cooling system is
10.6 US gallons in this example.
2. The measured concentration of ethylene gly-
col is 35% by volume (freezing point -6°F).
According to the table there are 3.7 US gal-
lons of ethylene glycol in the cooling system.
3. The required concentration of ethylene gly-
col is 45% by volume (freezing point -22°F).
According to the table, 4.8 US gallons of eth-
ylene glycol are required in the cooling sys-
tem.
4. Since the cooling system already contains
3.7 US gallons, fill another 1.1 US gallons of
ethylene glycol in the cooling system (4.8 -
3.7 = 1.1 US gallons).
For calculation Adequate protection against corrosion

Volume of ethylene glycol Cooling system
(%) 20 25 30 35 40 45 50 60 volume (US gal-
Ice slush forms (°F) 21 16 10 -6 -11 -22 -36 -58 lons)
1.3 1.6 2.1 2.9 3.2 3.7 4 4.8 7.9
1.6 2.1 2.6 3.7 4.2 4.8 5.3 6.3 10.6
2.1 2.6 3.4 4.8 5.3 6.1 6.6 7.9 13.2
2.4 3.2 4 5.5 6.3 7.1 7.9 9.5 15.9
2.9 3.7 4.8 6.6 7.4 8.5 9.2 11.1 18.5
3.2 4.2 5.3 7.4 8.5 9.5 10.6 12.7 21.1
3.7 4.8 6.1 8.5 9.5 10.8 11.9 14.3 23.8
4 5.3 6.6 9.2 10.6 11.9 13.2 15.9 26.4
Volume of ethylene glycol 4.5 5.8 7.4 10.3 11.6 13.2 14.5 17.4 29.1
(US gallons) 4.8 6.3 7.9 11.1 12.7 14.3 15.9 19 31.7
5.3 6.9 8.7 12.2 13.7 15.6 17.2 20.6 34.3
5.5 7.4 9.2 12.9 14.8 16.6 18.5 22.2 37
6.1 7.9 10 14 15.9 18 19.8 23.8 39.6
6.3 8.5 10.6 14.8 16.9 19 21.1 25.4 42.3
6.9 9 11.4 15.9 18 20.3 22.5 26.9 44.9
7.1 9.5 11.9 16.6 19 21.4 23.8 28.5 47.6
7.7 10 12.7 17.7 20.1 22.7 25.1 30.1 50.2
7.9 10.6 13.2 18.5 21.1 23.8 26.4 31.7 52.8
OPM 210 en-GB 33

Cooling system
Checking coolant level Checking antifreeze and cor-

The following instructions apply to Scania ex- rosion inhibitor
pansion tanks. For other types of expansion
tanks, follow the manufacturer's instructions. Designation Illustration
Refractometer
WARNING!
Never open the coolant filler cap when the en-

gine is hot. Hot coolant and steam may spray out
and cause burns.
305 523
If the cap has to be opened do it slowly and care-
fully to release the pressure before removing the
138008
cap. Wear gloves as the coolant is still very hot.
Note:
Use only pure fresh water that is free from parti-
1. Open the expansion tank cap and check the cles, sludge and other impurities.
coolant level.
The right coolant level on a cold engine is
even with the lower edge of the filler neck. 1. Pour a small amount of coolant into a con-
tainer and check that the coolant is pure and
The right coolant level on a hot engine is ap-
clear.
proximately 25 mm (1 in) over the lower
edge of the filler neck. 2. Change the coolant if it is contaminated or
cloudy.
IMPORTANT! 3. Measure the antifreeze content with a refrac-
tometer.
Do not top up large quantities of coolant through
the expansion tank. Top up in accordance with
the instructions in the section headed Changing The following rules apply to ethylene glycol-
coolant instead. based coolant:
Never fill a large amount of cold coolant in a hot • The antifreeze and corrosion inhibitor content
engine. There is great risk of cracks forming in must be minimum 35 percent by volume for
the cylinder block and cylinder heads corrosion protection to be sufficient.
Only pour pre-mixed coolant into the cooling • An antifreeze and corrosion inhibitor content
system. greater than 55 percent by volume impairs the
ability to protect against frost.
• If ice forms in the coolant, there are disrup-
2. Top up with coolant as necessary. tions initially, but there is no immediate risk
of damage. The engine should not be subject-
ed to heavy loads when ice starts to form.
OPM 210 en-GB 34

Cooling system
Antifreeze and corrosion in-

hibitor
Only the product Scania coolant, or other prod-
ucts that are tested to provide proper antifreeze
and protection against corrosion for Scania, may
be used in Scania engines. Products that do not
satisfy the requirements for use in a Scania en-
gine can result in faults in and damage to the
cooling system. This can lead to the invalidation
of Scania's warranty for faults and damage
caused by the use of inappropriate coolant.
The antifreeze and corrosion inhibitor used in
Scania engines should be of the ethylene glycol
type.
Scania concentrate
Designation Contents Part No. Volume Volume
litre US gallons
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 323 5 1.3
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 324 20 5.3
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 325 210 55
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 326 1,000 264
Scania Ready Mix

Designation Contents Part No. Volume Volume
litre US gallons
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 921 955 5 1.3
50/50
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 921 956 20 5.3
50/50
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 921 957 210 55
50/50
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 896 695 1,000 264
50/50
OPM 210 en-GB 35

Cooling system
Changing coolant
IMPORTANT!
Mix the coolant as specified under the section

Coolant.
Draining coolant
1. Remove the expansion tank cap.
2. Drain the coolant at the following two
points:
Lowest point of the cylinder block.
The lowest point of the cooling system.
3. Close the drain taps.
Environment
Avoid spillage and use a suitable container. Used

coolant must be disposed of as specified in na-
tional and international law.
OPM 210 en-GB 36

Cooling system
Filling coolant
Coolant trolley
333 980
IMPORTANT!
When it is necessary to fill a large quantity of

coolant, it must be pumped in from underneath.
This is to ensure that air does not get into the
cooling system, which can cause the coolant
pump to overheat.
1. Use a Scania coolant trolley, or other suitable

equipment, to fill with coolant through the
drain valve on the cylinder block. This facil-
itates the venting of the engine.
2. Start the engine when the cooling system has
been filled. Allow the engine to run for a
while. Then check the coolant level and top
up with coolant as necessary.
3. Air pockets may still be left in the cooling
system, which will disappear after the engine
has been operated for a period of time. It
may, therefore, need some topping up to start
with.
OPM 210 en-GB 37

Cooling system
Cleaning the cooling system External: Cleaning the radiator and

charge air cooler
1. Check that the radiator and the charge air
WARNING! cooler are not clogged on the air side and that
the cooling fins are not damaged.
To ensure proper handling of cooling system de-
2. Carefully scrape away any deposits from the
tergent, study the warning text on the package.
radiator cooling fins. Use a paraffin-based
engine cleaner if necessary.
3. Carefully straighten bent cooling fins using a
IMPORTANT! steel brush or the like.
Do not use caustic soda or other alkaline deter-

gent as this could damage the aluminium.
Note:
Clean the cooling system more often than speci-
fied in the maintenance interval if necessary.
OPM 210 en-GB 38

Cooling system
Internal: Removing oil and grease Internal: Removing deposits

1. Run the engine until it has reached operating 1. Run the engine until it has reached operating
temperature and then drain the cooling sys- temperature and then drain the cooling sys-
tem. tem.
2. Remove the thermostats. 2. Remove the thermostats.
3. Fill the system with clean, hot water mixed 3. Fill the system with clean, hot water mixed
with liquid dishwasher detergent intended with some commercially available radiator
for household machines. Concentration 1% detergent which is based on sulphamic acid
(0.1/10 litres). and contains dispersing agents. Follow the
4. Warm up the engine for approximately 20- manufacturer's instructions for the concen-
30 minutes. Remember to switch on the cab tration and cleaning period.
heating system, if one is installed. 4. Run the engine for the specified time. Re-
5. Drain the cooling system. member to switch on the cab heating system,
if one is installed.
6. Fill the system with clean, hot water and run
the engine for about 20-30 minutes. 5. Drain the cooling system.
7. Drain the water from the cooling system. 6. Fill the cooling system with clean, hot water
and run the engine for about 20-30 minutes.
8. Refit the thermostats.
7. Drain the water from the cooling system.
9. Fill the cooling system with new coolant fol-
lowing the specification under Coolants ear- 8. Refit the thermostats.
lier in the document. 9. Fill the system with new coolant following
the specification under Coolants earlier in
the document.
Environment Environment
Avoid spillage and use a suitable container. Used Avoid spillage and use a suitable container. Used
coolant must be disposed of as specified in na- coolant must be disposed of as specified in na-
tional and international law. tional and international law.
OPM 210 en-GB 39

Air cleaner
Air cleaner
Reading the vacuum indicator
If the indicator's red plunger is fully visible, re-
new the air cleaner filter element following the
instructions.
326 671
Renewing the filter element
WARNING!
Never start the engine without the air filter as this

could cause injury and severe engine damage. A B
Note:
Renew the filter element earlier than the mainte-
nance interval if the indicator shows red.
There is always a risk that the filter element will

be damaged when it is cleaned.
336 100
The filter element must not be cleaned in water
or be blown clean with compressed air.
A Vacuum gauge.
1. Remove the cover from the air cleaner. B Filter element.
2. Renew the filter element.
3. Carry out a check by inserting an inspection
lamp into the element and checking from the
outside that there are no holes or cracks in the
filter paper.
4. Assemble the air cleaner.
5. Reset the vacuum indicator by pressing the
button.
OPM 210 en-GB 40

Air cleaner
Renewing the safety cartridge
IMPORTANT!
When renewing the safety cartridge, take great

care to ensure that no dirt or other impurities get
into the engine. Do not remove the safety car-
tridge unnecessarily.
1. Remove the cover from the air cleaner.

2. Remove the filter element.
3. Remove the safety cartridge.
4. Fit a new, genuine safety cartridge.
5. Renew or clean the filter element.
6. Assemble the air cleaner.
OPM 210 en-GB 41

Fuel system
Fuel system Checking fuel level

• Check the fuel level and top up with fuel as
IMPORTANT! necessary.
The whole fuel system is very sensitive to dirt Note:

and even very small particles. Foreign particles The fuel system must be bled if the tank has been
in the system can cause serious malfunctions. It run dry. Refer to the Bleeding the fuel system
is therefore very important that everything is as section.
clean as possible when work is carried out on the
fuel system. Before starting work on the fuel sys-
tem, the engine must be washed. If possible, a
hot water wash should be used.
It is strictly forbidden to carry out any machining
work or work with compressed air near an open
fuel system.
Be extra careful and always use clean, lint-free
and dust-free clothes and gloves when working
on the fuel system. Scania recommends using
Tegera 848 gloves.
Clean tools before they are used and do not use
any worn or chrome-plated tools. Material and
flakes of chrome may come off.
Clean connections and the surrounding area be-
fore removal. When cleaning, cloths or paper
which shed fibres must not be used. Use clean
and lint-free cloths.
Plug or cover the connections during removal.
Also clean the connections before fitting the
components. Removed components should be
placed on a thoroughly cleaned, dust-free sur-
face. Cover with a lint-free cloth.
OPM 210 en-GB 42

Fuel system
Renewing the fuel filter

Hexagon socket, 1/2” drive, 36 mm
118 268
IMPORTANT!
Fit the filter elements in the filter covers before

placing them in the fuel filter housings or the fil-
ter elements may be damaged.
1. Unscrew the filter cover with the socket.

2. Lift out the filter cover and filter element.
The filter housing will drain automatically.
This applies only if the fuel tank is lower
than the engine. Otherwise the fuel shut-off
cock must be closed first.
3. Undo the removed filter element from the
cover by carefully bending it to one side.
4. Renew the O-ring in the cover. Lubricate the
O-ring with O-ring grease.
5. Check that the filter housing is drained of fu-
el. Contaminated fuel may enter the injectors
314 824
if the drainage does not work.
6. Press a new filter element into the snap fas-
tener in the cover.
7. Fit the filter element and cover in the filter
housing. Tighten the cover to 25 Nm (18.4
lbf/ft).
8. Bleed the fuel system after renewing the wa-
ter separating filter.
Environment
Avoid spillage and use a suitable container. Used

fuel must be disposed of as specified in national
and international law.
OPM 210 en-GB 43

Fuel system
Renewing the water separat- 1

ing fuel filter
1. Close the shut-off cock in the fuel pipe and
position a container under the filter.
2. Open the drain tap in the filter cover and let
the fluid run down into the container.
3. Unscrew the filter cover.
4. Unscrew the filter from the filter head.
5. Discard the old filter and use a new filter.
6. Lubricate the O-ring in the filter cover with
engine oil.
7. Screw the filter cover onto the new filter by
hand. Make sure that the drain tap is fully
closed.
8. Lubricate the O-ring on the filter with engine
oil. 2
9. Fill the width of the filter with clean fuel.
316 148
10. Screw the filter into position until the O-ring
rests against the filter head. Tighten the filter
another 1/2-3/4 turn by hand. 1 Shut-off cock.
11. Open the shut-off cock and check the system 2 Drain tap.
for leaks.
12. Bleed the fuel system.
OPM 210 en-GB 44

Fuel system
Bleeding the fuel system

1. Attach a clear plastic hose to the bleed nipple
on the fuel filter housing (1). Place the end of
the plastic hose in a container that holds at
least 3 litres (0.8 US gallons).
2. Open the bleed nipple and pump with the
hand pump until fuel comes out of the hose.
If the fuel system is empty, it is necessary to
pump approximately 100 strokes in order to
draw up the fuel. Depending on the installa-
tion, a much greater number of pump strokes
may be required before fuel comes out.
3. Pump until fuel without air bubbles comes 2
out, approximately 20 strokes.
4. Close the bleed nipple and remove the hose.
5. Transfer the plastic hose to the fuel manifold
314 909
bleed nipple (2).
6. Open the fuel manifold ventilating valve.
7. Pump with the hand pump until fuel without
air bubbles comes out, approximately 50
strokes.
8. Close the bleed nipple on the fuel manifold
and remove the plastic hose.
9. Pump approximately 20 strokes with the
hand pump until the overflow valve opens. A
hissing sound should be heard.
10. Start the engine. The engine should be easy
to start.
OPM 210 en-GB 45

Miscellaneous
Miscellaneous
Checking the drive belt
IMPORTANT!
Refit the drive belt with the same direction of ro-

tation as it had before removal.
Check the drive belt thoroughly, particularly at

the idler rollers.
312158
Check the drive belt for cracks.
106 229
The drive belt must be renewed if it has cracks.
OPM 210 en-GB 46

Miscellaneous
Check drive belt wear.
112 931
The drive belt is starting to become worn, but can be
refitted.
112 932
The belt is worn down to the cord. The drive belt
must be renewed.
Checking for leaks

• Start the engine.
• Check for oil, coolant, fuel, air or exhaust
leaks.
• Tighten or renew leaking connections. Check
the overflow holes which show whether the
O-rings between the cylinder liners and
crankcase are leaking.
• Check whether the drain hole on the coolant
pump is blocked. If there is a leak, renew the
seal in the pump or the complete coolant
pump.
IMPORTANT!
If serious leakage occurs, contact your nearest

Scania workshop.
OPM 210 en-GB 47

Miscellaneous
Checking and adjusting the

valve clearance
Special tools
Number Designation Illustration

99 309 Turning tool for rotating the flywheel from below.
142 238
99 109 Turning tool for rotating the flywheel from above. Can be used on newer
flywheels that are marked with TDC UP.
312 733
99 442 Setting tool
138 773
Torque screwdriver.
341 423
WARNING!
Block the starting device when working on the

a serious risk of injury.
Note:
Checking and adjusting valve clearances should
also be done one more time after the first 500
hours of operation. Then the normal interval will
follow (every 2,000 hours).
Valve adjustment should be carried out on a cold
engine.
OPM 210 en-GB 48

Miscellaneous
Checking and adjusting the valve

clearance
Check and adjust the valve clearance with the en-
gine cold.
Specifications
Valve clearance, intake 0.45 mm (0.018 in)
valve
Valve clearance, ex- 0.70 mm (0.028 in)
haust valve
Tightening torque
Lock nut for valves 35 Nm (26 lbf/ft)
Max. clearance between two valves under the

same valve bridge is 0.2 mm.
346 529
Readings can be taken from the flywheel through
openings in the flywheel housing either from
above or below depending on access when fit-
ting.
Note:
Valve transition occurs when the cylinder
switches from exhaust stroke to intake stroke.
The exhaust valve is closing while the intake
valve is opening.
310 343
Reading in the lower window: Openings for taking readings on the flywheel hous-
ing.
Rotate the flywheel in the normal direction of ro-
tation using turning tool 99 309. Read the mark
on the flywheel visible in the lower window of
the flywheel housing.
Reading in the upper window:
Fit turning tool 99 109 in the holes of the upper
window. Press the pinion into the external ring
gear and turn the flywheel with a ratchet handle
and a 14 mm socket. Read the mark on the fly-
wheel in the upper window of the flywheel hous-
ing.
OPM 210 en-GB 49

Miscellaneous
Adjust valves according to the table below. Fol-

low the respective column depending on whether
the reading is in the lower or the upper window.
Start adjustment at the top of the table.
1 2 3 4 5 6
319 705
Cylinder location.
Reading in the lower window of the flywheel
housing:
Mark on flywheel Valve transition on Adjust valves on cylin- Adjust injector

cylinder der
TDC down 1 6 2
120° 5 2 4
240° 3 4 1
TDC Down 6 1 5
120° 2 5 3
240° 4 3 6
Reading from the upper window of the fly-

wheel housing:
Mark on flywheel Valve transition on Adjust valves on cylin- Adjust injector

cylinder der
TDC Up 1 6 2
300° 5 2 4
60° 3 4 1
TDC Up 6 1 5
300° 2 5 3
60° 4 3 6
It is a good idea to mark the rocker arm with a

pen after adjustment to keep track of what has al-
ready been adjusted.
IMPORTANT!
Remember to remove the flywheel rotation tool

after adjustment.
OPM 210 en-GB 50

Miscellaneous
Checking and adjusting the unit in-

jector
Check and adjust the unit injector with the en-
gine cold.
Tightening torque
Lock nut for unit injec- 39 Nm (29 lbf/ft)
tors
WARNING!
When the unit injector is being checked and the

measurement is outside the setting dimension by
±0.5 mm, it is necessary to be very careful when
handling this unit injector. The spring is pre-ten-
sioned and can come loose, causing personal in-
jury.
1. Fit the setting tool with the metal plate

around the unit injector.
314 831
1
2. When adjusting, loosen the lock nut and ad-
just the unit injector with the adjusting screw
(1). The unit injector is correctly set when the
small piston (2) is level with the flat upper
surface of the tool. Use a finger to check.
Differences measured in tenths of millime-
tres can be felt. The setting dimension is 69.9
± 0.1 mm.
2
314 832
OPM 210 en-GB 51

Miscellaneous
144 015
The setting tool piston is above or below the flat The setting tool piston is level with the flat upper
upper surface of the tool. Adjust the unit injector. surface of the tool. The unit injector is correctly ad-
justed.
3. Tighten the lock nut after adjusting.

4. Remove the setting tool.
OPM 210 en-GB 52

Diesel
Diesel Temperature dependency of

the fuel
Composition of the fuel At temperatures lower than those specified for
The composition of the fuel is extremely impor- the fuel, paraffin wax may precipitate from the
tant for the operation and service life of the en- fuel and block filters and pipes. The engine can
gine and injection system. The engine output and then lose power or stop.
exhaust gases are also dependent on the fuel The fuel is adapted for use in the specific climate
grade. of each country. If a vehicle or an engine is to be
The requirements and testing standards for the operated in a temperature zone with a tempera-
most important characteristics are described in ture lower than normal, first identify the temper-
the Workshop Manual which can be ordered ature properties of that particular fuel.
from Scania dealers or directly from Scania. The properties of the fuel when cold can be im-
The fuel must conform to European standard proved by adopting one of the following meas-
EN 590. ures before the temperature drops:
The table shows some of the key properties. • Install an electric fuel heater if this particular
fuel is not suitable for the expected tempera-
ture and no fuel is available with the correct
Property Requirement temperature properties.
Viscosity at 40°C (104°F) 2.0-4.5 cSt • Add 0.5-2% alcohol (isopropanol) to prevent
Density at 15°C (59°F) 0.82-0.86 cSt any water in the fuel from freezing and form-
ing plugs of ice. Drain fuel tanks and drain or
Ignitability (CET rating) minimum 49 renew fuel filters regularly.
Flashpoint 56°C (132°F)
IMPORTANT!
Mixing kerosene or other paraffins with the fuel

Sulphur content of fuel is prohibited. The injectors may be damaged.
• A sulphur content of 0-2,000 ppm in the fuel Mixing petrol with the fuel is prohibited. In the
(0.2%) gives an oil change interval of up to long term petrol can cause wear in the injectors
500 hours. and engine.
• With a sulphur content of 2,000-4,000 ppm in
the fuel, the oil change interval is halved to
max. 250 hours.
• Maximum permitted sulphur content in the
fuel is 4,000 ppm.
Responsibility
IMPORTANT!
The machine operator is responsible for using

the correct type of fuel to ensure that local laws
are complied with.
OPM 210 en-GB 53

Diesel
Biodiesel (FAME) Use of fuel oil in stand-by

Scania uses the term biodiesel according to the generator sets
EN 14214 standard to refer to renewable diesel Long-term storage of diesel, where the diesel
made from greases or oils and methanol. The comes into contact with water, may lead to the
biodiesel should conform to the requirements of growth of micro organisms (bacteria and fun-
European standard EN 14214. For biodiesel gus). To avoid this in fuel used in stand-by gen-
EN 14214 the generic term FAME is frequently erator sets, i.e. ESP engines, Scania permits the
used. use of fuel oil according to DIN 51603-1 and
All Scania engines are approved for diesel ac- ÖNORM C 1109.
cording to the EN 590 standard. EN 590 contains Use of fuel oil is only permitted for ESP engines
up to 7% biodiesel in accordance with and under the following conditions:
EN 14214. PDE engines may use up to 100%
EN 14214 biodiesel. • The fuel must not be stored or used in temper-
atures below -10°C (14°F).
Maintenance intervals • The engine must not be equipped with an
With a greater mixture of biodiesel than EN 590, SCR system.
the renewal intervals for the following are
halved: Definition of ESP
• Fuel filter. ESP is an output class for stand-by generator sets
in accordance with ISO 8528, which states that
• Oil filter. stand-by generator sets may be used under vary-
• Oil. ing loads for a maximum of 200 hours/year.
The oil viscosity must be xW-40. ESP engines are intended for use as stand-by
power supplies in the efficient electrical net-
works in Europe, North and South America,
Australia, New Zealand, Japan and Taiwan.
OPM 210 en-GB 54

Preparing the engine for storage
Preparing the engine for Preservative fuel

storage Use diesel mixed with Lubrizol 560H or the
equivalent. Mix 1 cm3 (ml)/0.06 in3 Lubrizol
If the engine is not being used for an extended 560H in 10 dm3/2.3 US gallons of fuel.
period its cooling system, fuel system and com-
bustion chamber and outside must be protected
against rust. WARNING!
An alternative to preparing the engine for long-
term storage is to start the engine and warm it up Lubrizol 560H contains aromatic hydrocarbons
every 6 months. which are hazardous to health.
• Use spot extractors where there is a danger of
vapour build-up.
Handling the engine • Wear protective goggles and gloves when
handling the fuel.
The engine can normally stand idle for up to 6
months without preparation. For longer periods • Do not use contaminated clothing.
of downtime, the following measures should be • If it gets in your eyes: Flush with a gentle jet
taken. These measures provide protection for ap- of water for at least 15 minutes and contact a
proximately 4 years. doctor.
Preparations for storage: • If it gets on your skin: Wash with soap and
water.
• Thoroughly clean the engine. • If you inhale it: Fresh air, rest and warmth.
• Run the engine for a specific period using • Store in well-sealed containers in a dry, cool,
special preservative fuel, oil and coolant. place out of the reach of children.
• Otherwise prepare the engine for storage (fil-
ter renewal, lubrication, etc.). Lubrizol is flammable and has a 2A fire rating.
The flashpoint is +27°C/81°F. In case of fire: Ex-
tinguish with carbon dioxide, powder or foam.
Preservative coolant
If the engine is to be stored with a full cooling
system, use coolant containing 50 percent glycol Preservative oil
by volume. Glycol without nitrite-based inhibi-
tor should be used. Example: BASF G48 or Suitable preservative oils are supplied by most
BASF D542. oil companies. Example: Dinitrol 40 or equiva-
lent.
WARNING!
Ethylene glycol can be fatal if ingested. Avoid

contact with the skin.
OPM 210 en-GB 55

Preparations for storage 10. Drain the preservative oil from the engine.
Fill with new engine oil immediately or
when the engine is to be reused.
Environment
11. Drain the coolant if the engine is not to be
stored with coolant in the system. Plug and
Use a container to avoid spills when draining the tape all coolant connections if the engine is
oil and coolant. Dispose of used fluids through to be stored without a cooling system.
an authorised waste disposal contractor.
12. Air cleaner: Clean or renew the filter ele-
ment.
1. Drain and flush the cooling system. Top up 13. Cover air intakes and exhaust pipes.
with preservative coolant.
14. Alternator and starter motor: Spray with wa-
2. Warm up the engine on normal fuel. Stop the ter-repellent anti-corrosive oil, CRC 226,
engine and drain the oil. LPS1 or the equivalent.
3. Renew the fuel filter. 15. Spray the outside of bright engine parts, first
4. Fill the engine with preservative oil up to the with penetrating preservative oil such as
minimum level on the oil dipstick. Dinitrol 25B and then with Dinitrol 112 or
5. Mix preservative fuel in a can. Detach the
the equivalent.
fuel pipe at the feed pump suction line and Clearly mark the engine with the storage prepa-
connect a hose from the can. ration date, and state that the engine must not be
6. Detach the fuel pipe at the overflow valve started or cranked.
and connect a return hose to the can.
7. Start the engine and run it at about 1,000 rpm
for 20-25 minutes.
8. Stop the engine, remove the hoses and con-
nect the normal fuel pipes.
9. Remove the rocker covers and lubricate the
valve mechanisms with plenty of preserva-
tive oil. Refit the rocker covers.
Note:
Do not remove the injectors.
OPM 210 en-GB 56

Batteries Storage
Remove the batteries and trickle charge them at After the preparations, the engine should be
the battery charging station. This does not apply stored in a dry and warm place (room tempera-
to batteries specified as maintenance-free by the ture).
manufacturer.
The same applies to short-term storage, even if
the engine has not been prepared for storage as When the engine is to be taken into
above. operation again
1. Remove plugs and tape from coolant connec-
WARNING! tions, air intakes and exhaust pipes.
2. Fill the cooling system with coolant. For
Wear gloves and protective goggles when charg- more information refer to Maintenance.
ing and handling batteries. The batteries contain 3. Check the oil level in the engine or top up
a highly corrosive acid. with fresh engine oil.
4. Lubricate the valve mechanisms and their
pushrods and valve tappets as well as the in-
jector mechanisms with plenty of oil.
5. Drain the preservative fuel from the fuel
manifold and fuel filter.
6. Connect and bleed the fuel system. For more
information refer to Maintenance.
7. Wash off any preservative oil on the outside
using white spirit.
OPM 210 en-GB 57

Technical data
Technical data
General data
Number of cylinders and configuration 6, straight

Working principle 4-stroke engine
Cylinder diameter (mm/in) 130/5.12
Piston stroke (mm/in) 160/6.30
Displacement (dm3/in3) 12.7/775.0
Firing sequence 1-5-3-6-2-4
Compression ratio 17.3:1
Engine direction of rotation viewed from rear Anti-clockwise
Fan direction of rotation viewed from front Clockwise
Cooling Coolant
Valve clearances, cold engine:
Intake valve (mm/in) 0.45/0.02
Exhaust valve (mm/in) 0.70/0.03
Number of teeth on the flywheel 158
Low idling speed (rpm) 500-1,050
Maximum full-load speed (rpm) 2,100
Fuel Diesel
Approximate weight, without coolant and oil (kg/lb) 1,050/2,315
Lubrication system
Oil volume See Maintenance

Oil cleaning Centrifugal oil cleaning
Oil cooler Coolant cooled, full
flow
Oil filter Paper filter from Scania
Interval between oil changes (h) 500
Oil pressure (bar)
Normal with the engine at operating temperature, operating speed 3-6
Minimum permitted at idling speed 0.7
Crankcase pressure with closed crankcase ventilation (mbar) -5.4 to 2.0
OPM 210 en-GB 58

Technical data
Injection system
Type PDE (unit injector)

Control system EMS
Fuel filter Paper filter from Scania
Fuel filter with water separator Paper filter from Scania
Cooling system
Coolant volume, excluding radiator (dm3/US gallons)

DC13 071A 17/4.5
Other engine types 16/4.2
Coolant volume, including radiator (dm3/US gallons)
DC13 071A 39/10.3
Other engine types 38/10.0
Coolant temperature (°C/°F) 90-95/194-203
Number of thermostats 1
Thermostat opening temperature (°C/°F) 80/176 and 87/189
Intake system
Permissible pressure drop in the intake system with cleaned or new fil- 30
ter (mbar)
Permissible pressure drop in the intake system with blocked (dirty) fil- 65
ter (mbar)
Electrical system
Type 1-pin, 24 V, DC
Starter motor, standard equipment 1-pin, 24 V, 5.5 kW
Alternator, standard equipment 1-pin, 28 V, 100 A
OPM 210 en-GB 59

Scania Assistance
Scania Assistance
Wherever you are, you can always get assistance
from the Scania service organisation, Scania As-
sistance, all day, every day of the year.
Always call the contact for your country.
AR 0800 999 722 642 IE +353 71 9634000

AT +43 1 256 44 11 IT +39 0461 996 222
AU 1300 SCANIA KR +82 1588 6575
1300 722642 LU +32 226 400 000
BE +32 2 264 00 00 MA +34 91 678 92 13
BG +359 886 660001 MX 01 800 4SCANIA
BR 0800 019 42 24 NL +31 70 4182666
CA +1-800-2-SCANIA NO +47 223 217 00
CH +41 800 55 24 00 PL +48 602 622 465
CL 188 800 722 642 PT +48 91 678 9247
CZ +420 225 020 225 RO +40 723 27 27 26
DE +49 261 887 8888 SE +46 42 100 100
DK +45 333 270 44 SK +421 903 722 048
ES +34 91 678 80 58 TR +90 212 335 04 40
FI +358 10 555 24 TZ +255 78 472 2642
FR +33 2 414 132 32 US 1-800-2-SCANIA
GB 0 800 800 660 UY 0800 8351
+44 1274 301260 ZA 0800 005 798
GR +30 6944 420 410 +27 11 661 9823
HU +36 209 727 197
Other countries: +46 8 52 24 24 24

Note:
Calls will be recorded for training purposes.
OPM 210 en-GB 60

Date 11.06.2018
DnD 150 DC13
Rev 00
Pump DnD 150
P a g e | 67
DnD-05
COUPLING


Flexible Tyre
    
    

    

Easy Installation
    
   

Maintenance and Lubrication



    

Taper Flanges
     
    



Taper Bush
     
   

Tension Member
   
    

Elastomeric Compound
    
   
   




Whatever Your Need For Couplings

 Has Them
SIZES F40-60
SIZES F70-250
SIZES F70-120
(Reversible)



Sizes 40-60 Sizes 70-120 (Reversible)
L L L R F F
L R L R
M M M M M
G G
E E E
H OD H OD H E E
OD FD FD FD H FD OD H FD OD
Type B Type F Type H Type FH Type FH
Sizes 70-250
L L L
F G F G F G
M M M
E E E
OD H FD OD H FD OD H FD
Type B Type F Type H
DIMENSIONS OF  - FLEX FLANGES TYPES B, F, H & FH

   
 

             
         
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  
                
                  
                  
                  
                
                  
                  
                  
                
                  
                  
                  
                

  
 

  









Sizes 40-60 Sizes 70-120 (Reversible)
L L L R F F
L R R
M M M M M L
G G
E E E E E
H OD H OD H H FD OD H FD OD
OD FD FD FD
Type B Type F Type H Type FH Type FH
Sizes 70-250
L L L
F G F G F G
M M M
E E E
OD H FD OD H FD OD H FD
Type B Type F Type H
DIMENSIONS OF  - FLEX FLANGES TYPES B, F, H & FH

   
 

             
         
                  
                  
                  
                
                  
                  
                  
                
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  
                  

  
 

  







  

NOTE:  



1.  5. 
 
 
2.  
 
 

  

    

    
3. 
   

  
     

 6. 
 
 
4. 





 
               
                
               
                


Date 11.06.2018
DnD 150 DC13
Rev 00
Pump DnD 150
P a g e | 68
DnD-06
VACUUM PUMP
SAFEW PBECAUTIONS
DO NOT DESTROY
This manual contains important safety OPERATORS
information, and should be made
available to all personnel who operate MANUAL &
andlor maintain this product. Caref ully
read this manual before attempting to
operate or perform maintenance on
PARTS LIST
this compressor.
Models V23SNZ}STI
v244N244Tt
v255N2557
SINGLE.STAGE & TWO STAGE
rsoll Rand
AIR SOLUTIONS
REFER ALL COMMUNICATIONS TO THE NEAREST
INGEBSOLL-RAND SALES OFFICE OR YOUR DISTRIBUTOH OR FOTM NSCD - 471 REV 01
E-MAIL AT airsolutionsindia@irco.com 2000 - Jan 2O06
UNDERTAKING AS TO SAFETY
We have ensured that our equipment is safe and without
risk to the health of the workers when properly
used in accordance with the information and advice relating
to its use contained in the instruction Bool</
ortance that you use our equipment only after going
r alia, detailed instructions, information and advice
y. The equipment is solid and supplied to you on the
ensure that the equipment sord and suppried

workers when properly used.
o, ," lli;:iH'ffx?ilj:11",.:;:y[Til::i["Jff:l?
WARNING
STATEMENT CONCERNING THE USE OF THIS EOUIPMENT FOR BREATHING
AIB AND/OR AOUA LUNG SERVICE.
,.THE
VACUUM PUMP IS SUITABLE
TION, THE VACUUM PUMP IS NOT
ACUUM PUMP TO BE CAPABLE OF
ALIZED EQUIPMENT O PBOPERLY
LE FEDERAL, STATE AND LOCAL LAWS, RULES, REGULATIONS
AND coDES, sucH AS, BUT Nor LlMlrED To, osHA 29 cFR tgto.tgi.
coMpRESSED GAS ASSoclATtoN coMMoDrry
SPECIFICATION G-7-1966. GBADE D BBEATHING AIR, AND/OR USER FAIL
TO ADD SUCH SPECIALIZED EOUIPMENT AND
PBOCEEDS TO USE THE VACUUM PUMP FOR BBEATHING AIR SERVICE,
THE PURCHASEB/USEB ASSUMES ALL LIABILITY
RESULTING THEHEFROM WITHOUT ANY RESPONSIBILITY OR LIABILITY
BEING ASSUMED BY INGERSOLL-BAND
COMPANY.
THE PURCHASER IS URGED TO INCLUDE THE ABOVE PROVISION IN ANY

AGBEEMENT FOH ANY RESALE OF THIS
VACUUM PUMP.
FOB ADDITIONAL INFOFMATION AND WARNINGS, SEE THE PARTS

LIST FOR THIS MACHINE-
SAFETY PRECAUTIONS
WHERE LUBRICATING OIL IS PBESENT IN THE VACUUM PUMP DISCHABGE,
AN AFTERCOOLER SHOULD BE INSTALLED
IN THE FINAL VACUUM PUMP DISCHARGE LINE; IT SHOULD BE
MOUNTED AS cLoSE AS PoSSIBLE To THE VA.UUM
PUMP.
WHEN INSTALLING A NEW VACUUM PUMP IT IS ESSENTIAL TO REVIEW
THE TOTAL PLANT AIB SYSTEM. THE USE OF
PLASTIC OB NON-METALLIC BOWLS ON LINE FILTEBS WITHOUT METAL
GUARDS CAN BE HAZARDOUS.
A PBESSUBE BELIEF VALVE MUST BE INSTALLED IN DISCHARGE PIPING
BETWEEN THE VACUUM PUMP AND ANY
POSSIBLE RESTRICTION, SUCH AS A BLOCK VALVE, CH
INSTALL A PBESSUBE RELIEF VALVE COULD RESULT IN O
PUMP AND PERSONAL INJUBY. BEFER TO INSTSRUCTION
THOSE RESPONSIBLE FOR INSTALLATION OF THIS EOUIPMENT
MUST PROVIDE SUITABLE GROUND. MAINTENANCE
CLEARANCE AND LIGHTING ABBESTOBS FOR ALL ELECTRICAL COMPONENTS
AS STIPULATED IN O.S.H.A. 1910-2OB
THBOUGH 1910.329.
WHEN A RECEIVEB IS INSTALLED ITIS RECOMMENDED THAT OCCUPATIONAL
SAFETY AND HEALTH STANDARDS AS
COVERED IN THE FEDERAL REGISTER, VOLUME 36 NUMBEB 105 PABT
II PARAGRAPH 191 0.i69 BE ADHERED
INSTALLATION AND MAINTENANCE TO THIS BECEIVER. To IN THE
ALL ELECTHICAL INSTALLATION MUST BE IN ACCOBDANCE WITH BECOGNIZED

ELECTRICAL CODES. BEFORE WOBKING
ON THE ELECTBICAL SYSTEM BE SURE TO CUT OFF THE ELECTRICAL
SUPPLY Tnon,T iie SYSTEM BY USE oF A
MANUAL DISCONNECT SWITCH. DO NOT RELY ON THE STARTER TO
CUT OFF THE ELECTBICAL SUPPLY.
FAILURE TO HEED ANY OF THESE WAFNINGS MAY RESULT IN AN ACCIDENT
CAUSING PERSONAL INJURY OB PBOPERTY
DAMAGE.
lndex
Section - 1
General Description
1.1 Single Stage Vacuum Pumps
1.2 Two Stage Vacuum Pumps
Section - 2
Instruction & Start up Recommendation
2.1 Location & Foundation
2.2 lnlet Piping
2.3 Electrical
2.4 Fuses
2.5 Vacuum Pump Piping
Section - 3
Prestarting Checks, Lubrication & Adujstments
3.1 lmport Servicing & Operating Procedure 9
3.2 Prestarting Checks 9
3.3 Operating Checks 10
3.4 Vacuum Pump Lubrication 10
Section - 4
Maintenance
4.1 Routine lnspection Schedule 11
4.2 Torque Values 12

4.3 Best lnstruction & Adjustment 13
4.4 Piston Ring Replacement 13
4.5 Separating the Piston from Rod 14
4.6 Crankshaft Bearing Replacement 14
4.7 Crankpin Bushing Reptacement 14
4.8 Oil Seal Replacement 15
4.9 Precautions for Extended Shutdown 15
Section-5
Trouble Guide
5.1 Trouble Shooting Chart 16
Section-6
6.1 Vacuum Pump lubrication chart for Type 30 Vacuum Pumps 19
Section-7
7.1 Part List 20
TYPE.3O VACUUM PUMPS
SECTION 1 . GENERAT INFORMATION
This booklet covers Type-30 single and two-stage vacuum pumps. The installation, operation and
maintenance information given in this booklet is applicable to all vacuum pumps regardiess of construction.
For detailed information not covered, refer to the nearest lngersoll-Rand branch office.
1.1. Single-Stage Vacuum Pumps: Single-stage For maintaining the vacuum within predetermined
vacuum pumps are either-cylinder machines or limits, the pump may be manually controlled, relief
multiple cylinder machines with the inlet side of each valve controlled, or regulated by automatic start and
cylinder connected to a common manifold. See stop control. With this latter type of regulation, a
Figure 1. The basic principle of operation of a single- vacuum switch is tapped into the system under
stage vacuum pump follows: On the suction stroke vacuum and wired back to the driving motor.
of the piston(s), air or gas is drawn from the chamber Changes in vacuum will make and break the
being evacuated into the cylinder(s)through the inlet electrical circuit, automatically starting and stopping
manifold and inlet valve(s) located in the air head(s). the driving motor, thereby maintaining the vacuum
On the upward stroke of the piston(s), the inlet within the prescribed limits.
valve(s) closes and the discharge valve(s) opens, 1.2. Two-Stage Vacuum Pumps: Any unit with more
permitting the air that was evacuated from the
than one cylinder and the manifold arrangements
chamber to be exhausted through the discharge
shown in Figure 2 is a two-stage vacuum pump. Two-
valve(s) either to atmosphere or to a recovery system.
stage vacuum pumps pull higher vacuums than
A silencer (optional) may be installed in the discharge
single-stage units and operate as follows: On the
of units discharging to amosphere.
suction stroke of the first stage piston(s), air or gas
OTSGHARGE
INTAKE
INTERSTAGE MANIFOLO
INTAKE
INTAKE
Figure 1 - Single-stage Vacuum Pumps
Efficient oil control is established by a direct Figure 2 - Two-stage Vacuum pumps

connection between the intake (vacuum) side of the
system and the interior of the crankcase through a is drawn from the chamber being evacuated and
breather tube. As a result, a pressure balance is
created between both sides of the pistons which
minimizes loss of oil past the piston rings. ln addition,
the crankcase vacuum tends to keep the oil dry by
flashing off condensible vapors that may be pulled since these two stages are connected through the
over from the system. interstage manifold, the first-stage cylinder(s) are put
under a vacuum by the second-stage. This action the crankcase vacuum tends to keep the oil dry by
increases volumetric efficiency and contributes to a flashing off condensible vapors that may be pulled
higher final vacuum. The discharge stroke of the over from the system.
second-stage piston then discharges the air either
to atmosphere or to a recovery system. A silencer For maintaining the vacuum within predetermined
(optional) may be installed in the dis-charge of units limits the pump may be manually controlled, relief
valve controlled or regulated by automatic start-and-
discharging to atmosphere.
stop control. With this latter type of regulation, a
Efficient oil control is established by a direct vacuum switch is tapped into the system under
connection between the interstage manifold and the vacuum and wired back to the driving motor.
interior of the crankcase through a breather tube. As Changes in vacuum will make and break ihe
a result, a nearly equal pressure balance is created electrical circuit, automatically stafiing and stopping
between both sides of the low-stage piston(s) which the driving motor, thereby maintaining the vacuum
minimizes loss of oil past the piston rings. ln addition, within the prescribed limits.
SECTION . 2
INSTALLATION AND START.UP RECOMMENDATIONS
Step 1 the air filter/silencer to a source of cleaner air or use an
optional heavy duty filter. lf, it is found necessary to
Unload the vacuum pump from delivering vehicle-
install inlet piping, make the line as short and direct as
the purchaser must arrange for adequate lifting
possible and-as large, or larger than the diameter of
equipment at the job site.
the inlet connection at the vacuum pump. The inlet
IMPORTANT NOTE : The purchaser assumes title piping must increase in diameler for evefy 50' (15.25
to the vacuum pump equipment at the manufacturers m) and 100' (30.5m) increase the pipe diameter at the
shipping dock, immediately upon receipt of the mid-point in the length, i.e. if the total length is B0' (24.4
equipment. lt should be inspected for any damage m) increase the pipe diameter at the 40' (12.2 m) point.
that may have occurred during shipment. Attach the air cleaner to the end of the inlet air line
Step 2. and if the inlel is piped outdoors, it should be hooded
Check vacuum pump nameplate to be sure the unit to prevent the entrance of rain cr snow See Figure
is model and size ordered. Do this before uncrating. 2-1. Fine airborne dust, such as cement and rock
Check Receiver Nameplate to be sure the tank is dust require specialfiltration equipment not furnished
adequate for pressure at which you intend to operate. as standard equipment on this vacuum pump. Such
filtration equipment is available from your loc-al
Step 3....... lngersoll-Rand Distributor.
Check motor nameplate to be sure motor is suitable
for your electrical conditions (Volts - Phase - Hertz). A well ventilated location should be selected for this
machine when operating in very damp climates or
Step 4........
under conditions of high humidity. These atmospheric
2.1. LOCATION & FOUNDATION conditions are conducive to the formation of water in
ln cold climates, it is desirable to install the vacuum the crankcase, and if adequate operation and
pump within a heated building. Choose a clean, ventilation are not provided, rusting, oil sludging and
relatively cool location, and provide ample space rapid wear of running parts will result. This is
around the unit for cooling and general accessibility. parlicularly true when operating on very intermittent
Place the beltwheel side toward the wall, leaving at duty applications.
least '15" (380 mm) for air circulation to the beltwheel
The unit may be bolted to any substantial relatively
fan. The location should also be near a source of level floor or base. If such a surface is not available,
water and a drain line to simplify piping connections
an adequate base must be constructed. Should a
if a water-cooled aftercooler is to be used. (Note : lf
concrete base be necessary to make certain the
a detached receiver is to be used, consider placing
foundation bolis are positioned correctly to accept
the receiver outdoors to provide more effective heat
the receiver feet, and that these bolts project at least
dissipation. Keeping in mind that condensed water
1' (25.4 mm) above the surface of the foundation.
in the receiver may treeze).
Step 5........ The unit must be levelled and bolted in a manner
which avoids pre-stressing the receiver in order to
2.2. INLET PIPING prevent bibration and ensure proper operation. The
lf the air in the vicinity of the vacuum pump is unduly following technique is recommended for anchoring
difty or contains corrosive fumes, we recommend piping this unit.
A. Tighten evenly, and to a moderate torque, the
nuts of any three of the four receiver foundation
holes. Check the unit for level. lf the unit is not -/5 x -7.38 LG.HEX BOLT
level, insert metal shims, as shown in Figure 2- \ol o So Oi.
2, under one or two of the feet to obtain level
and retighten the nuts. 1.0 DlA. x 6.0 LG.
M.S. PIPE
OUTSIDE ROUGH GROUTING
POUR GROUT AFTER 48 HRS

OF OUTSIDE GROUTING
3.0 x 3.0 x.38 THK.
M.S. PLATE
SUGGESTED FOUNDATION DETAIL
INLET AIR Figure 2.3. - Suggested Foundation detail

FILTER/SILENCER
THE VACUUM PUMP SHOULD BE NEVER BE
OPERATED WHILE MOUNTED TO THE SHIPPING
CRATE SKID.
Step 6
2.3. Electrical
Figure 2-1. lnlet piping arrangement. (See electrical diagram on Page (23)
B Note the distance the unanchored foot is elevated To avoid invalidating your fire insurance it is
above the base and insert a metal shim of equal advisable to have the electrical work done by a
thickness under this foot to provide firm support. Iicensed electrician who is familiar with the
Shims must be at minimum the same dimension regulations of the National Electrlcal Code and the
as bottom of foot. requirements of the local codeOR .DGFAS.
USE OI.ITY NON-SHR N KING GROUT A}JO PACX WELL
(GRqJT TEVEL NOT TO BE ABOVE THE BOTTOf,I OF FOOT) RECOMMENDED CABLE SIZE
ts
H.P ALUMINIUM COPPER
'1
1.5 1.5
1.5
-t
2
1.5
1.5
1.5
5 1.5 1.5
7.5 2.5 1.5
10 2 5 2.5
12.5 2.5
15 64
L
20 10 6
16 10
Figure 2-2. Methods of Levelling Unit.

16 ___ 16_ _
les
l
25 16
C. After all shims are inserled and the unit is level,
pull up the nuts on all receiver feet to a moderate
40 zs- --25
l
(not excessively tight) torque.

50 35
TYPE : PVC LOW CORE TENSION ARMOURED
D. Check for receiver stress by loosing nuts (one at
(PVC TROPEDORE ABMOURED) 4 CORE CABLE
a time), and note any upward movement of the
*DGFAS : DIRECTOR GENEBAL, FACTORY ADVISE
mounting foot. Any noticeable movement
indicates that step B must be repeated. SERVICE AND LABOUR INSTITUTE BOMBAY.
Severe vibration will result when nuts are pulled The wire size recommended in the above table are
suitable for the vacuum pump unit. lf other electrical
down tightly and feet are not level. This can lead to
equlpment is connected to the same circuit, the total
welds cracking or fatigue failure of receiver. This is
electrical load must be considered In selecting the
a very important parl of installation.
proper wire sizes. A burned out motor due to low (B) Piping from the chamber being evacuated to the
voltage may result, unless it is properly protected. pump must be as short and straighl ds possible. The
Before wiring the vacuum pump to the power supply, connection to the chamber should be near the top
the electrical rating of the monitor, as shown on the and all changes in pipe direction are to be gradual to
motor nameplate, must be checked against the reduce friction Iosses. Pipe diameter must
electrical supply. lf they are not the same; do not correspond to the pump intake opening diameter.
connect the motor. lncrease the diameter at least one size for every 20
It is important that the wire used be the proper size feet of length. lf the total length of piping is between
and all connections secured mechanically and 20 and 40 feet, we recgmmend that the increase in
electrically. The size of the wire shown in the table pipe diameter is made at the midpoint in length, i e.,
above is a safe guide. for a 30 foot length, increase the pipe diameter at
lf the distance is more than 100 feet (30.5 m), larger the 15 foot point
wrre will probably be necessary and your electrilal (C) The interior of the intake pipe is to be clean and
contractor or local electric company should be special care is to be taken in the threading of pipes
consulted for recommendations. The use of ioo small and the selection of fittins. All joints must be
wire results in sluggish operation, unnecessary absolutely tight.
tripping of the overload relays or blown fuses. (D) lt is very important that the inlet air to the pump
Step 7. be kept clean at all times. Dirty, contaminated air
not only reduces the capacity of the pump but also
2.4 FUSES
causes premature wear of working parls. All vacuum
Fuse failure usually results from the use of fuses of pumps must be positively protected against water
insufflcient capacity. lf fuses are lhe correct size and vapor, dirt, entrained moisture or corrosive gases.
still fall, check for conditions that cause local heating, The use of a pipe line filter desrgned for this purpose
such as bent, weak or corroded fuse clips. will protect the pump against these elements under
average service conditions. The filter selected should
I necourraENDED HRc FUSE BATTNG AMD ] combine extra large filtering area and capacity with
i te. _ !.o.L_ _lf4E qElfA
low flow resistance. lnstall the filter close to the pump
intake as shown in Figure 6 and make ceftain the air
flow through it is in the direction indicated by the
arrow on the filter housing. Note : lf the pump is
required to evacuate a moist or liquid filled chamber
and there is a possibility of an abnormal quantity of
liquid being drawn into the cylinders, a scrubber tank
should be installed next to and ahead of the filter.
The scrubber tank is merely a large volume chamber
that traps and collects liquid as air passes through
it. Always install a drain valve in the bottom of the
20 50 32 tank. See Figure 6 for general installation
25 OJ D' recommendations covering the scrubber tank.
(E) To facilitate servicing and maintenance, a full size
plug or gate valve is to be installed on the vacuum
system side of the filter. lf a scrubber tank is used,
100
install the valve on the vacuum system side of the
100 tank. ln addition, a small vacuum breaker valve is to
be installed between the larger plug or gate valve
2.5. VACUUM PUMP PIPING
and the vacuum pump intake. See Figure 6.
The location of the intake and discharge connection (F) lf the discharge is to be piped away from the
for the various type vacuum pumps is shown in pump, use the same diameter pipe as the discharge
Figure 1 and 2. For efficient, trouble free operation, connection and make provision for draining
the following recommendations are to be observed condensate from this line by either sloping the prping
when connecting the vacuum pump to the chamber down from the pump or installing a suitable
being evacuated. The general arrangement drawing condensate trap in the line. Note : the sitencer (if
shown in Figure 6 is applicable to all vacuum pump used) may be removed from the pump discharge and
types and may be used as a guide during installation. installed in the end of the discharge pipe.
Vacuum Switch & Gauge..... A vacuum switch and/
(A) All piping should drain away from the cylinders.
or gauge are factory installed only if so indicated on
(Locate the pump above the chamber being your order. lf the customer intends to install these
evacuated).
items in the system, observe the following
instructions.
PRESSURE SWITCH (lf used)
(TO BE TAPPED TO CHAMBER BEING
VACUUM EVACI.JATED AIIO WIRED TO DRIVIIIG
MOTOR.)
BREAKER
VALVE
E*
SILENbE# l(
tr.t
(tt used) B=
_-
J<
EF
(J -+ TO VACUUM
i
a CHAMBER OR
SILETICER IiISTALLED IiI OISCHARGE
IF DISCT{ARGE 15 iIOT PIPEO AWAY FROM SYSTEM
PUMP.
ffIOBE USED OIILY UIIDER SEVERE PLUG OR

oPERATI'IG Co[DtTrOfl S, SEE GATE VALVE
PARAGRAPH 7.
c-ttg
DRAIN VALVE
Figure 6. - General piping arrangement lor Vacuum Pumps (Note : The pump shown above is a single-stage unit'
See Figure 2 for intake & discharge location of two-stage units)
(A) lnstall the vacuum switch and/or gauge at a point (B) The vacuum swltch may be mounted in any
in the system that registers the actual vacuum being position and supported by the connecting piping or
pulled, such as the vacuum chamber. Do not install its mounting bracket. Wire the switch to the motor or
these items in a position or locations that will permit magnetic starter according to the schematic diagram
condensate to drain into them and keep the accompanying the switch.
connecting tubing as short and direct as possible.
SECTION .3
PRE.STARTING GHECKS, LUBRICATION & ADJUSTMENTS
3.1. IMPORTANT SERVICTNG AND OPERATING PROCEDURE

Do not service the pump, such as checking oil, draining condensate from the scrubber tank or filter,
l
i,r
etc., without stopping the pump and isolating it from the vacuum system. To isolate the pump, close
the valve in the intake line and open the vacuum breaker valve. See Figure 6 for locations.
(2) As an initial precaution against loss of efficiency and oil we recommend that all bolts be checked
and tightened after the first B or 10 hours of operation.
(3) lnitial oil changes are to be made afterthe first 50 to 100 hours o{ operation. See paragraph'10 for
details. _ l
3.2. PRESTARTING CHECKS (B) Check the electric current voltage specifications
(A) Before starting a new unit, fill the crankcase to on the motor nameplate against the electrical service
the overflow point with lubricating oil. Check the available. Make certain the motor is correctly wired.
motor bearings for lubrication. See paragraphs 10 Particularly check the wiring and voltage of dual
and 11 for lubrication instructions. voltage motors.
(C) Turn the vacuum pump over a few revolutions
by hand to see that everything is free and in working
condition.
(D) Check the tension of the belts on belt-driven units,
or the alignment of the coupling on flexible coupled
units. See page g o110 for instructions.
Figure 7. - Filling with oil.

(E) Remove tools, rags and any other objects from
We recommend the use of a non-detergent,
the vicinity of the pump before throwing the switch. naphthenic base oil containing rust and oxrdation
inhibitors. The oil viscosity should be selected for
the ambient temperataure rmmediately surrounding
the unit when it is in operation. See the following
table.
Oil Viscosity Table
Temp. Range Viscosity (SSU @ .100o F)
4000 F & Below 150
40o F to B0o F 500
Figure 8 - Checking for freedom of rotation
B0o F to 125a F 750
(F) Momentarily starl the unit to make certain that
the direction of crankshaft rotation is the same as The exact type and brand of tubricating oil best suited
shown by the directional arrow on the pump fly-wheel. for your use depends upon such operating conditions
lf rotation is incorrect, interchange two of the three as application, duty-cycle, atmospheric conditions
leads on 3-wire polyphase motors. For other types are outlined to a reputable oil dealer for specific
of motors, follow the reversing instructions given on recommendations.
the motor nameplate.
Crack oilcapacities are as follows : Models V23A &
(G) Stan the unit. lt will be necessary for the operator V235 - 7lB quart (0.82 tt.); Models V244 - 1-3/4 quarts
to stop and start the pump unless it is automatically (1.65 ltr.); V255 - 2l1lZ quarts (2.36 ttr.); Modets 7V
controlled by a vacuum switch. lmportant : before &7V2 - 2-1/2 quafts (2.36 ttr.); Modets 15V, 15VT,
operating the pump become familiar with the 20V&20VT-5quarts.
"lmportant Servicing and Operating procedure,, given
above.
3.3. OPERATING CHECKS
Satisfactory operation of any piece of mechanical
equipment depends, to a large degree, upon
adhereance to a preventive maintenance schedule.
The "Routine lnspection & Service" guide given on
page 19 should be observed to obtain optimum
performance at minimum costs.
3.4. VACUUM PUMP LUBRICATION
initially every 50 to 100 hours of operation. After the

operator has observed the condition of the oilfrom a
number of these changes, the Iength of time between
changes can be extended up to 500 hours if so
warranted. Note : see "lmportant Servicing and
Operating Procedure" above before checking or
changing oil.
CAUTION
When changing oil, never use kerosene or
gasoline to flush out the crankcase. The use of
such cleaning agents is dangerous and their use
must be absolutely prohibited. Use a regular
flushing oil for this purpose.
10
SECTION - 4
MAINTENANCE
4,1 ROUTINE INSPECTION SCHEDULE . Check the belt tension. Tighten the belt as
needed.
. lnspect the lubrication oil for contamination.
Before attempting any repair work on the unit, Change if necessary.
be certain the isolation switch is in the "of" . Check, clean and lubricate the motor bearings.
position, or the wiring is disconnected from . Clean exterior of the vacuum pump.
the line. Blow down the pressure from the 3 MONTHS/sOO HOURS OF OPEBATION
reservoir and isolate the unit from any outside (wHICHEVER COMES FIRST)
source of air pressure. These simple . Change the lubricating oil with recommended oil
precautions will prevent accidents. only.
DAILY OR BEFORE EACH OPERATION :
. Tighten all the bolts with optimum torque value
indicated in torque chart.
. Check lubrication oil level in the crankcase. Fill . Check piston rings and waring suffaces.
as needed. . Check the condition of oil seal for wear out.
. Drain condensate from the receiver tank (if Replace the seal if necessary.
automatic drain valve is not provided, open the . Re-tighten intercooler and aftercooler tube
manual valve and despose the condensate fittings.
accordingly). . Tighten the clamping bolts for intercooler,
. Check for existance of any unusual noise and aftercooler and guard.
vibration.
. 6 MONTHS/1OOO HOURS OF OPERATION
Examine visually, earth connections, overall
(WHTCHEVER COMES FIBST) :
condition of the motor and the cable.
. Check motor windings for over heating.
. lnspect and if necessary clean the vacuum pump
valves.
. Ensure beltguards and covers are securely in
. Clean the external surface of the cylinder,
place.
intercooler and aftercooler with a jet of air.
. Ensure area around the vacuum pump is free
. Clean the winding of motor subjected to corrosive
from rags, tools, debris and flammable or
or other elements, also apply a coat of air drying
explosive materials.
varnish or epoxy paint necessary.
WEEKLY : . Check grease in ball bearing and make it up
. lnspect and clean the air inlet filter. where necessary (taking care to avoid over filling)
, Clean the cooling fins and exterior of cylinder, 12 MONTHS/2OOO HOURS OF OPERATION
intercooler and aftercooler. (WHTCHEVER COMES FTRST) :
. Check safety/relief valves by pulling rings and
. lnspect and replace the filter element.
replace whichever do not operate freely.
. Blow out and clean windings of protected type
. Inspect and replace the sealing gaskets.
motors, situated in dusty locations.
. lnspect and replace the worn parts.
. Examine starting equipment for burnt/pitted . Clean the valve assembly and top face of the
piston if carbon deposits are found on it.
contacs where motor is started and stopped
f requently.
. Check all high speed bearing speed bearings and
renew if necessary.
. Blow out debris by opening manual drain valve
. Blow out all windings thoroughly with clean dry
(if automatic drain valve is not provided and
atl.
despose the condensate accordingly).
. Celan all the dirt and oily windings.
MONTHLY : . Renew switch and fuse contacts if badly pitted.
. lnspect for air leaks. Squirt soapy water around . Check alignment between motor and vacuum
joints during vacuum pump operation and watch pump.
for bubbles. . Takeout the aftercooler and intercooler tubes and
. Check tightness of screws and bolts. Tighten as blow off the dirt and deposits on the internal
needed. surfaces with the safety solvent.
11
GENERAL
The maintenance section of this book covers only those operation with which maintenance personnel may not be
too familier. lt is expected that the average mechanic's training and experience will permit him to perform the
more common maintenance functions without the need for detailed instructions.
4.2. TOHQUE VALUE TABLE

BOLT SIZE TOROUE
NATIONAL COARSE GRADE 2 GRADE 5 GRADE 6
Dia. Pitch Ft. Lbs. Kg. Meters Ft. Lbs. Kg. Meters Ft. Lbs. Kg Meters
114'20 4 trtr
6 ,82 9 1.24
1/16', - 18 B 1 .10 12 1.66 1B 2.49
3/8', - 16 15 2.10 23 c 10 31 4.29
7116' - 14 24 J.JI Jt) 4.98 51 7.05
112' - 13 37 5.12 56 7.74 BO 11.06
9116',-12 53 733 ot
ol 11.20 't
16 16.04
s/8'- 1 1 68 9.40 113 15.63 160 22.12
314" - 10 131 18.12 203 28.07 286 39.ss
We recommend the use of a torque wrench on all bolts, capscrews, and nuts using the values in the above
table. The values given are for threads lubricated with oil or grease.
To determine the grade of the bolt or capscrew being tightened, use the following information.
Grade 2 : No markings or vendor identification on lhe head.
Grade 5 : Letter 'S' or 3 lines and/or vendor identification on the head.
Grade B : Letter "V" or 6 lines and/or vendor identification on the head.
Description Torque Value (LB-FT) Description Torque Value

HP Head Bolt 75 LB-FT HP lnlet Valve 11-15 LB-|N
LP Head Bolt 75 LB-FT LP lnlet Valve 25-30 LB-|N
Cylinder Flange Bolt 50 LB-FT HP Outlet Valve 1 1-15 LB-|N
Frame Cover Bolt 17 LB-FT LP Outlet Valve 25-30 LB-|N
Shaft Cover Bolt 17 LB-FT Belt Wheel 60 LF-FT
Crank Pin Cap Bolt 11 LB-FT Center HP Air Head Bolt 10 LB-FT
Cover Unloader Bolt 11 LB-FT Center LP Air Head Bolt 14-16 LB-FT
4.3. BEST INSTALLATION AND ADJUSTMENT and installing new bolts is to loosen the anchor screws.
When installing new belts, do not pry the belts over and the belt tightener screw Figure 6-1 and push the
the pulley grroves. The proper method of removing motor toward the vacuum pump. Use the tightener
screw to adjust bolltension on new belts.
It is important that belts be properly adjusted. A belt
that is too loose willslip and cause heating and wear,
and a belt that is too tight may overload the bearings.
A quick check to determine if belt adjustment is proper
may be made by observing the slack side of the belt
TIGHTENING
scREll for a slight bow when the unit is in operatioh. See
Figure 6-2. ll a slight bow is evident, the belt is usually
adjusted satisfactorily. However, the recommended
method of checking belt tension is by the more
accurate spring scale measuremenl method that
follows :
Figure 6.1- Belt Adjustments
12
4.4. PISTON RING REPLACEMENT
Figure 6.2- Belt Adjustments

A. Measure the belt span (1) as shown in Figure 6.3
B. At the center of the span (1), apply a force
(perpendicular to the span, by attaching a spring
scale to the two outside belts. The force applied A general rule in determining if a vacuum pump,s oil
to the spring scale should be sufficient to deffect consumption is excessive is to consider a minimum
the belts 1/64' (.396 mm), thus, the force applied oil consumption to be approximately (50) horse_
to the spring scale should defect the belts to 1.9/ power-hours per 25 ML. To apply this rule, consider
'16" (39.6 mm).
the size of a vacuum pump, for example; a five horse_
power unit uses 100 ML of oil in twenty hours of
operation. Five horse-power multiplied by twenty
FI'IBELI SPAN hours equals one-hundred horse power hours,
divided by 100 equals t horse-power per 1 ML. Any
vacuum pump using more than 50 ML of pil per one
hundred horse-power-hours would be classed as not
meeting commercial standards and would require
corrective action, such as replacement of the piston
rings. lf it has been determined that replacement of
the piston rings is necessary, lngersoll-Rand
Company, recommends that a complete new set of
rings be installed and that these instruction be used
Figure 6.3- Spring Scale Method
as a guide for piston ring replacement.
C. When the belts are deffected the necessary New replacement piston rings are of the quick-
distance, compare the spring scale reading (in seating-type in that they are distinguished by their
lbs. force) with the value given in the following narrow seating edge where they contact cylinder wall.
table. Compression rings are classed as "B" type rings and
are a single piece, taper-faced style in taht they have
STANDARD BELT TENSION a slight taper machined on their outer surface to
provide line contact with the cylinder wall for quicker
Belt Normal 150% Normal
scating and better oil control.
Type Tension Tension
One or several of these compression rings may be
A 1% lbs. (.565 kg) 1% tbs. (.Bs kg)
used depending on the pressures involved. Oil rings
are classified as "H" type, or "M'' type rings. The "H"
lf the reading is between the value for normal tension type ring is a single-piece, non-ventilated, beveled
and 150% normaltension, the belt tension should be scraper style which allows it to act as a combination
considered satisfactory. A reading below the value oil scraper and compression sealing ring.
for normal tenslon indicates the belt slack should be Either one or two of these oil rings may be used on a
reduced, and conversely, a reading exceeding the piston.
value for 150% normal tension indicates the belt slack
The "M" type ring is a three piece, ventilated, chrome
should be increased. Experienced has shown that a
plated, steel rail style ring. This style ring utilizes an
new drive can be tightened initially to two times
expander which exerts a uniform pressure all the way
normaltension to allow for any drop in tension during
around two independent, thin, cylinder contacting
run rn.
rails, the rails being held apart by an open separator.
The style of ring provides maximum oil drainage with
the most uniform and positive conformability.
13
The style ring may be used in conjuction with an "H" D. Pull the cylinder up over the piston.
type ring when two oilcontrolwiper rings are required.
E. Remove crankpin cap from the end of the
4.5. SEPARATING THE PISTON FROM THE ROD crankshaft and pull the connecting rods of the
To separate the piston from the connecting rod: crankpin bushing.
proceed as follows : F. Remove the old crankpin bushing from the
A. Disconnect any assemblies or piping that may crankshaft throw and place a new bushing on
prevent removing the cylinder. Now, take out the the crankpin.
cap screws securing the cylinder to the frame G. Replace the connecting rods, crankpin, cap and
and pull the cylinder over the piston. frame end cover.
B. To avoid bending the connecting rod when H. Oil the cylinder bore and replace the cylinder.
driving out the piston pin, we recommend
removing the piston and rod assembly from the l. Replace the air head and any other assemblies
crankshaft. To do this drain the oilfrom the frame
or piping that were removed.
and remove the frame end cover. Then take off J. Refill the frame with oil.
theend of the crankshaft and pull the connecting
CRANKSHAFT ASSEMBLY REPLACEMENT
rod off its throw.
A new crankshaft assembly includes bearings,
C. Remove the piston pin lock rings from their spacers, crank disc, etc., all of which are installed as
grooves and with a dowel of approximate size
a unit. To remove the old crankshaft and install a
and soft hammer, drive out the piston pin. new one, proceed as follows :
lmportant : To prevent piston distort on during
this operation, play between the piston pin A. First remove the belt wheel, belt wheel key and
bosses and connecting rod must be eliminated shaft end cover. Next, drain the frame oil and
by inserting fork type shims of the necessary remove the frame end cover.
thickness between the rod and boss. B. Remove the cylinder to frame cap screws and
D. Before installing the new pin, oil the walls of the pull the cylinders over the pistons. Remove the
pin align the connecting rod in the piston and connecting rods from the end of the crankshaft,
drive in the new pin using an appropriate dowel and take the snap ring from the outer bearing. lt
and a soft hammer. may be necessary to drive the crankshaft
endwise before removing snap ring.
E. When the piston pln is in place full the lock rings
back in their grooves. C. The crankshaft assembly ia a moderate press
fit in the frame and may be forced out by tapping
F. Put the connecting rod back on the crankpin and
the belt wheel end of the shaft with a lead
replace the crankpin cap and frame end cover.
hammer.
G. Oil the cylinder bore and replace the cylinder. D. Prepare the new crankshaft assembly for
Replace the air head and any other assemblies
installation by removing the snap ring from the
or piping that were removed.
outer bearing by grasping it near the end and
4.6. CRANKSHAFT BEARlNG REPLACEMENT springing it from the groove.
lf bearing replacement is necessary, we recommend E. The new crankshaft may be inserted into the
the installation of new crankshaft complete (with frame from the frame end cover side. Since the
bearings attached.) lngersoll-Rand cannot accept assembly is a moderate press fit, it may be
responsibility for the successful operation of the forced into position by tapping it with a lead
vacuum pump unless a genuine I R crankshaft hammer. (Be carefull to strike the center of the
complete is used as a replacement. Refer to the shaft since an off center blow may spring it.)
appropriate parts list for ordering instructions.
F. The assembly must be driven in until the snap
4.7. CRANKPIN BUSHING REPLACEMENT ring groove in the outer bearing clears the end
To replace the crankpin bushing of the frame by about 1/6" (1.59 mm). Replace
the snap ring by putting one end in the groove
A. Drain oil from the frame. and sprining the ring into place.
B. Remove the frame and cover. G. Tap the crankshaft back until the snap ring is
C. Remove the air head and cylinder to frame cap tight against the frame.
SCTCWS.
14
H Before replacing the shaft end cover (includes 4.9. PRECAUTIONS FOR EXTENDED
oil seal), make ceftain that there are no burrs SHUTDOWN
on the belt wheel end of the crankshaft and that
the edges of the key way are smooth and slighily Whenever the unit is taken out of service for long
rounded to prevent damage to the oil seal. When
periods of time, certain precautions must be
satisfied that the crankshaft is smooth, replace taken to prevent general deterioration.
the shaft end cover. As an added precaution A. All interior surfaces of the unit should be
agaisnt cutting the oil seal, an assembly tool can protected against rust by draining the frame and
easily be made in the form of a truncated cone refilling it with a rust inhibiting oil. The unit should
of .003" (.076 mm) brass shim stock. See Figure now be operated for fifteen minutes and the orl
6.4. should be fogged into the unit's intake, thus
coating all internal surface. Leave the rust
inhibiting oil in the frame. Note . When putting
the unit back into service, replace the rust
inhibiting cil with conventional lubrication oil.
B After this operatron, all openings are to be taped
shut to prevent moisture from entering the unit.
U Drain the air receiver of all moisture and store
the unit in a dry sheltered location.
D. Follow the manufacturer's instructions for storing
the electric motor or gasoline engine.
Figure 6.4- Oil Seal Replaceement
L Re-assemble the rest of the vacuum pump,

using caution when replacing the cylinders over
the pistons. We recommend the use of a piston
ring vacuum pump in this operation.
J. Fill the frame with oil.
4.8. OIL SEAL REPLACEMENT
A. Remove the belt wheel, key and shaft end cover.
The oilseal may be removed from the cover by
prying under the inside lip with a pinch bar, or
driving it out with a metal rod.
B lnsert the new seal with the sealing lip facing
toward the inside of the frame and coat the
outside diameter of the seal with shellac or pipe
compound. Press the seal into the shaft end
cover with a vise or in a press. Note : Protect
the parls from damage by serrated vise jaws by
padding the vise jaws.
C. After the seal has been installed in the shaft end
cover, it is returned to its original location by
sliding it over the end of the crankshaft, as
described in paragraph (H) of Crankshaft
Assembly Replacement.
15
TROUBLE GUIDE
5.1 TROUBLE SHOOTING CHART
TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
Oil/Lubricant . Clogged or dirty suction filter Clean the filter element as per the
Pumping instructions given in the maintenance
section.
. Lubricant oil viscosity too low. Drain the existing lubricant and refill with
proper one.
. Lubricant oil Ievel too high. Check for optimum level of oil.
. Detergent type lubricant being used Replace the lubricant with a non-detergenl
lubricant having rust and oxidation
inhibitors.
. Piston rings damaged or worn (broken, Replace piston rings.
rough, scratched, excessive end gap
or side clearance).
. Piston rings not seated, stuck in grooves Clean and adjust the piston rings,
or end gaps not staggered Replace as required.
. Cylinders or pistons scratched, worn Repair or replace the cylinders or the
or scored. pistons are required.
Beduction ar . Clogged or dirty suction filter. Clean the filter element as per the
delivery instructions given in maintenance pert
. Valve leaking, broken carbonised, or unecK valves. ulean or replace as
loose. Air passages restricted. required.
. Air leaks in piping (On machine or Detect the leakage and solve it
external system).
. Piston rings damaged or worn (broken, Beplace piston rigs
rough, scratched, excessive end gap
or side clearance.
. Piston rings not seated, stuck in grooves Clean and adjust the piston rings.
or end gaps not staggered. Replace as required.
or scored. pistons as required.
.. Moisture in frame . Detergent type lubricant being used. Replace the lubricant with a non-detergent
or Busting in lubricant having rust and oxidation
cylrnders inhibitors.
. Exteremely light dury cycles Run vacuum pump for longer duty cycles.
. Vacuum pump located in damp or Relocate the vacuum pump or add
humid spot. crankcase heaters.
Safety/relief valve . Valve leaking, broken, carbonised Check valves. Clean or replace as
pops or loose. Air passages restricted. required.
. Defective safety/relief valve. Replace safety/relief valve.
,, Knocks or rattles . Loose beltwheel or motor pulley or Check beltwheel, motor pulley and shaft
excessive end play in the motor shaft Repair or replace as required.
or scored pistons are required.
16
TROUBLE PROBABLE CAUSE COHRECTIVE ACTION
:. Knocks or rattles . Carbon on top piston. Use proper solvent to remove it or apply
(Continue)
emery paper of fine grade and clean the
surface of the piston
. Leaking, broken, carbonized or loose Check valves CIean or replace as
valves. Air passages restricted. req uired.
. Worn or scored connecting rod, piston lnspect all. Replace the parts which are
prn or crank pin bush. defective
. Defective ball bearing on crankshaft or Replace the crankshaft assembly complete
on motor shaft. with bearings (refer maintenance section
for details.)
:. Motor does not . lmproper Iine voltage. Check line voltage & change lines as
run required.
Poor contacts on motor or starter Ensure proper contacts on motor and
terminals. starter terminals.
lmproper starter heaters nstall proper starter heaters
. Poor power regulation (unbalanced line) Consult with local power company.
Motor overloads . Lubricating Oil viscosity too high. Drain the existing lubricant and refill
or draws loose. Air passages restricted. with proper one.
excesstve currenl
. Poor contacts on motor or starter Ensure proper contacts on motor and
terminals. starter terminals.
. lmproper line voltage. Check line voltage & change lines as
required.
. Poor Power regulation (unbalanced Iine) Consult with local power company.
" lmproper staner heaters lnstall proper starter heaters.

. Leaking, broken, carbonized, or loose Check valves Repair or replace as
valves. Air passages restricted. required.
. Worn or scored connecting rod, piston lnspect all. Replace the parts which are
pin or crank pin bush. defective.
. V-belt is pulled too tight. Adjust proper belt tension.
. Defective ball bearing on crankshaft Replace the crank shaft assembly
or on motor shaft. complete with bearings (refer maintenance
section for details.)
. Cylinders or pistons scratched, worn or Repair or replace the cylinder or pistons
or on motor shaft. as required.
." Excessive starling . Air leaks in piping (on machine or Detect the leakage and solve it.
& Stopping external system.)
. Receiver check valve leaking. Tighten or replace the check valve
. Excessive condensate in the receiver Drain the receiver
Vacuum pump .lnadequate ventilation around Relocate the vacuum pump for aOequate
runs excessively beltwheel. air-flow.
hot. . Lubricant oil level too low. al_qck for optimum level of oil.
. Receiver check valve leaking. Tighten or replace the check valve.
Leaking, broken, carbonised or loose Check valves Repair or replace as
valves. Air passages restricted. required.
17
TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
.r Vacuum pump . V-belt is pulled too tight. Adjust proper belt tension.
runsexcessively
hot. (Continue) . Wrong beltwheel direction of rotation. Check motor wiring for proper connections
Compressor . Loose beltwheel or motor pulley, Check beltwheel, motor pulley and shaft.
Doesn't come up Excessive end play in the motor shaft Repair or replace as required.
to speed . lmproper line voltage. Check line voltage & change lines as
required.
. Poor contacts on motor or starter Ensure proper contacts on motor and
terminals. starter terminals
. Improper starter heaters. lnstall proper starter termrnals.
Abnormal piston, . Clogged or dirly suction filter, Clean the filter element as per the
ring or cylinder instruction given in the maintenance
wear section.
. Lubricating Oil viscosity too low or Drain the existing lubricanr and refill
too high. with proper one.
. Lubricant oil level too low. Check for optimum level of oil
. Detergent type lubricant being used. Replace the lubricant with a nondetergent
lubricant having rust and oxidation
inhibitors.
. Extremely dusty or pollutted Route air inlet filter to a clean air source.
environment. Use heavy duty filter element.
Lights flicks or dim . lmproper line voltage Check line voltage & change lines as
when compressor required.
rs runnrng.
. Poor contacts on motor or stafter Ensure proper contacts on motor and
terminals. stafter terminals.
. lmproper stafter heaters, lnstall proper starter heater.
. Poor power heaters. lnstall proper starter heater.

. Poor power regulation Consult with local power company
(unbalanced line)
':il Vibration & noise . Loose beltwheel, motor pulley or motor lnspect all. Repair or replace
with excessive end play in the shaft. as required.
. Clamping bolts are loose. Tighten the bolts to the optlmum torque
level as per torque chart.
o Suction filter open or loose assembly. Close it and apply sealant for leakproof
assembly.
High discharge . lntercooler fins are deposited with dust Clean the intercooler fins externally.
temperature or di11.
. Prolonged operation Operate with intermittent duly cycle
. Lubricant oil level too low. Check for optimum level of oil
18
SECTION .6
6.1. VACUUM PUMP LUBRICATION CHART FOR TYPE 30 VACUUM PUMPS
LUBRICATING OIL RECOMMENDATIONS
we recommend the use of a non-detergent, parafinic base oil containing a rust and oxidation inhibitor. The
viscosity should be selected for the temperature immediately surrounding "
the unit when it is in operation..
lngersoll-Rand recommends the use of High Performance Lubricant, T30
Distinct which is specially formulated by
Castrol, or use Equivalent.
Product Characteristics*
Test Method Typical
Appearance Visual Bright & Clear
Kinematic Viscosity, At 40oC, Cst lP71 220
Viscosity lndex tP226 96
Flash Polnt, COC, oC lP36 225
Conradson Carbon Residue, wt7" lP 13 0.5
TAN, mg KOH/g tPl 1.1
Rust Preventive Characteristics ASTM D 665 (A & B) Passes
* These
are typical figures ancl do not constitute specifications.
19
SECTION .7 : PART LIST
GENERAL INFORMATION the particular location or function on this unit. The
The following is an illustration list description of the relationship of a subassembly or component part to
parts required to maintain and repair your unit. Also higher assemblies is shown by indentation and bullet
include is a list of Cost Saving Kits which ar'e designed symbols. Always provide the parl description when
for routine maintenance and repair tasks. ordering.
DESCRIPTION QUANTTTY (OTY.)
The pafts list contains a breakdown of the unit into Quantities listed in this column reflect the number of
assemblies, subassemblies and detail parts. Each each item used in the next higher assembly, and are
assembly is followed by its subassemblies and not necessarily the total quantity of the part in
component pafts, which are indented with "bullet" (.) complete model. Specify desired quantity when
symbols to show the relationship to the next higher ordering.
assembly. Assemblies which are broken down in SPARES
separate lists and illustrations list the appropriate . Class 1 - Minimum Recommended quantity for
figure number and page reference after the item Domestic Service where interruptions in service are
description
not important.
EXPLANATION OF COLUMNS . Class 2 - Average. Suggested quantity for Domestic
Each parts lists is divided into the following columns: Service where some interruplions in continutty of
REFERENCE NUMBER (REF. NBR.) service are not objectionable.
Each illustration rs accompanied by the list of parts, . Class 3 - Maximum. Suggested for Export Service
either on the same or on consecutive pages. This or for Domestic Service where interruptlons in service
column lists the figure number for the illustration, are objectionable.
followed by the call-out number on the illustration COST SAVING KITS
which identifies that item. The reference number is
Cost Saving Kits for your unit are Iisted on the
usually not required for ordering parts or kits.
following page. These kits provide all of the parls you
The following abbreviations might be used in the will need to perform common repair or scheduled
Reference Number column: maintenance tasks, such as piston ring replacement
. Nl = Not illustrated or valve replacement. The reference numbers listed
. REF = Reference Only. You may be referred to a in the contents column reflect the parts included in
Figure and Page noted in the Description Column. each kit, and correspond to the reference numbers
for the parts as they appear throughout this manual.
PART NUMBER
The quantity of each item included in tghe kits is the
All items listed in this section bear lngersoll-Rand same as that listed for the item under the given
part numbers, which are listed in this column. The reference number. When ordering the kits below, use
part number must always be specified when ordering the Description and Part Number as shown.
spare or replacement parts.
ORDERING INSTRUCTIONS
The following abbreviations might be used in the Part
AII parts listed in this section can be ordered through
Number column:
your local lngersoll-Rand Distributor. Consult the
. NA = Not applicable. Directory of Distributors included with the vacuum
. NSS = Not Sold Separately. Such items must be pump to find the distributor in ycur area.
ordered as part of the next higher assembly; or, where When ordering, always provide the following
applicable, as part of a Cost Saving Kit. information.
. ** = Part Number will vary. Specify the vacuum The MODEL NUMBER and SERIAL NUMBER
pump discharge pressure and complete motor stamped on the vacuum pump nameplate.
nameplate data when ordering.
The FORM NUMBER of this rnanual, as listed in the
DESCRIPTION lower right-hand corner on the front cover.
The descritpion column identifies items by standard The QUANTITY, DESCRIPTION & PART NUMBER
name, or nomenclature, and modifiers. The modifiers of the part(s) you are ordering.
are used to identify specific characteristics (i.e.
Refer to the example on the inside back cover of this
dimensions, capacity, pressure setting, etc.) and/or
manual.
5
-u
DISCHARGE
P
g\
!
Q\
INLET
.V
FIGURE 1. TYPICAL TWO-STAGE VACUUM ARRANGEMENT.
v2447
PABT DESCRIPTION EC. SPARES
NBR
1-1 951 01 457 95033338 95033270 PLUG, PIPE - SOUARE COUNTERSUNK

1-2 951 041 96 950s41 28 950541 44 CAPSCREW - HEX
1-3 95053567 950021 68 950021 6B CAPSCREW - HEX
1-4 9567 4701 305s0735 303451 85 WASHER FLAT 2
1-5 37129210 37129236 32223018 MAN IFOLD INLET/DISCHARGE
1-6 30294912 30294854 30294854 GASKET - MANIFOLD
1-7 30284111 30284095 CONNECTION MANIFOLD
'1-8
30284095 CONNECTION MANIFOLED
.1-9
302841 03 CONNECTION MANIFOLD
21
.0- 30
32 31
14
\
&
_
)@_
22 \:\\
DETAIL A
A. -p\ 15
21
tt
12
11 16
29
4
1
I 10
2g --<lr' --,
\
{
d
19
FIGURE 2. TYPICAL VACUUM FRAME ASSEMBLY

FOR MODELS V235, V235T, V244, v244T, V255, V255T.
22
DESCRIPTION REC. SPARES
t-l 9534465 1 95344651 I 9s344651 PLUG, PIPE 1/2

2-2 95640009 NIPPLE LONG, 1i2 x 2
t-J 321 79061 COUPLING PIPE 112'
2-4 302'16055 3021 6055 I 3021 6055 PLUG OIL FILLER COMPLETE
1 -tr.
9s0221 58 95022158 | 950221 5B . O RING
t-o
a_7
951 05243 CAPSCREW - HEX 5/16 - iB x 7/8,
l-o 951 05243 951 05243 CAPSCREW - HEX 5/16 - 18 x 7/8
2-9 95079984 CAPSCREW - HEX 5/i 6 - iB x 1 il4,'
2-10 95674651 9567465'l 9567465 1 GASKET COPPER WASHER . 5/16'
2-11 37127123 37127800 32281719 COVER, FRAME END
2-12 30299226 3043931 I 30439427 GASKET FRAME END COVER
2-13 30291 892 32145146 30212914 WHEEL, V-BELT
2-14 95077798 95077798 95077798 . NUT - HEX 1t2 - 13
2-15 9s71 6890 9571 6890 9571 6890 . LOCKWASHER, SPRING - 1/2
2-16 95053682 95053682 95053708 . CAPSCREW - HEX 11213
2-17 32061 293 90799289 90799289 L0CKWIRE, 12 GA x 5
2-18 30278709 30278667 30278667 CAPSCREW - HEX
2-19 3021 031 4 3021 0298 3021 0280 - CRANKPIN
CAP
2-20 320041 45 32004152 321 g8t 60 ROD, CONNECIING
2-21 95.105243 951 05243 951 05243 CAPSCREW - HEX S/i6 - 1B x 7/8
2-22
2-23 37127032 37127677 37127958 COVER, SHAFT END
2-24 32204521 32204539 32204s70 SEAL OIL
2-25 30295034 30294995 3028053.t GASKET SHAFT END COVER
2-26 70235346 70235353 7023536 1 CRANKSHAFT - COMPLETE
954331 73 954331 73 954331 73 . KEY WOODRUFF
3028981 3 302 1 01 99 3021 01 65 BUSHING, CRANKPIN
30222327 32012932 s2203192 FRAME, VACUUM PUMP
9534465 1 95200333 95200333 PLUG PIPE - 3/4"
OPTIONAL EOUIPMENT
DETAIL A
95053070 95053070 95053070 CAPSCREW - HEX 114 - 20 X 112'
32270639 3227 0647 32270654 BAFFLE, LOW OIL LEVEL SWITCH
70235262 70235262 70235262 SWIICH, LOW OIL LEVEL 3/4' NPT
32035479 32035479 32035479 WASHER - 1/4'
23
.. g E-r,
-14
-14
16
-? 15
fi-l
8
6
22- I
'2 sP
E- 'w
23
9-
)26 1- 24
v<
€
I
6
27
FIGURE 3. MODEL V235 BARE VACUUM.

DESCRIPTION
3-1 371 31 11 7 | TUBE ASSEMBLy BREATHER _ 5/1 6' DtA 1

J-l 9s082483 | C0NNECTOR, TUBE _ 5/16 X 1/B' 1
9s031860 | ELB0W, TUBE - 5/16 X 1/B '1
3-4 95033585 | PLUG, ptpE - soltD SQUARE HEAD 1/B 'I
3-5 95053567I CAPSCREW -HEX1t2-13x1 114" 2

3-6 95104196I CnpSCnEw -HEX1t2- 13 X 2' ,
3-7 956t4t01 | wnsHrn, FLAI - :rtz"
4
3-B 37129210 | MANtFoLD, TNLET/DTSCHARGE
2
3-9 30294912 I GASKEI, MANIFOLD
4
3-'10 30284111 | CONNECT|ON, MAN|F0LD
4
3-1 1 95103792 | cnrscnew - HEX 3i8.16x1.1t2, 6
3-12 95103800 | cApscREW- HEX3/8.16x j.3/5 2
3-1 3 3t1zt3s4 I RtRHeno
Z
3-14 32232t61 I ensxrt ATRHEAD
2
3-1 5 32141194 I SpnCrnrvRLVE ASSEMBLY
2
3-'16 9541 6335 | . NUT - HEX 1/4.20
4
3-17 3203s479 | . LOCKWASHER,SpRtNG_1/4
4
3-1 8 32035461 | . scREW, FtLLtsrER HEAD jt4 20x1t2,'
4
3-1 I 32]39891 J . SHtM, Ftr!GER VALVE 'l
3-20 30221170 | . VALVE. FTNGER
Z
3-21 37127248 I . SpRCeR
1
3-22 30280499 | GASKET, SPACER
Z
3-23 9503s333 | CAPSCREW - HEX 3/B - 16 x 7/8,
B
3-24 95674677 | C0PPER - 3/B'WASHER
o
3-25 37130630 | CYLTNER-3'
2
3-26 30294227 I GASKET, cyltNDER FLANGE
I
3-27 32194276 I SET, R|NG - 3'
2
3-28 30292429 | PtST0N, AtR - C0MPLETE _ 3'
2
35151067 | . RtNGL0CK
2
25
16
,i?
-+
p
I
1
'\-
9--
'-+.-2s
-go
l-
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
t.
I
I
,I-\-
FIGURE 4. TYPICAL BABE VACUUM FOR MODELS V244, V255.
26
REC. SPARES
DESCRIPTION
4-1 37004066 37131273 TUBE ASSEMBLY BREATHER - 5/16" DIA 1
4-2 95082483 95082483 CONNECTOR, TUBE - 5116 x 118', 1
4-3 95031 860 95031 860 ELBOW, TUBE - 5116 xllB" 1
4-4 95033585 95033585 .1/B'

PLUG , PIPE - SOLID SOUARE HEAD 1
4-5 950021 68 950021 6B CAPSCREW-HEX5/B-11 2

4-b 958i6975 95054144 CAPSCREW-HEXsi8-11 2
1-l 303451 B5 303451 B5 WASHER, FLAT - 5/B' 4
4-8 37129236 32223018 MAN IFOLD, INLET/DISCHARGE 2
4-9 30294854 30294854 GASKET, MANIFOLD 4
4-1 0 30284095 CONNECIION, MANIFOLD 4
4-11 30284095 CONNECTION, MANIFOLD 2
4-12 302841 03 CONNECIION, MANIFOLD 2
4-13 951 041 96 CAPSCREW - HEX112 - 13 X 2" B
4-14 32279408 32279048 WASHER FLAI 112' 8
4-15 951 041 96 CAPSCREW - HEX 112- 13 X 2" 12
4-16 95468443 CAPSCREW - HEX 3/B - 16 X 1 1/B' 4
4-17 9567 4677 WASHER, FLAT - 3/B' 4
4-18 37127362 37127370 AIRHEAD 2
4-19 32267551 32267536 GASKET, AIR HEAD 2
4-20 32024283 32027740 SPACER/VALVE ASSEMBLY 2
4-21 9541 6335 9s41 6335 . NUT - HEX1t4 - 20 4
4-22 32035479 32035479 . LOCKWASHER, SPRING. 1/4' 4
4-23 32035461 32035503 . SCREW, FILLISTER HEAD 114 - 20 4
4-24 32217382 32217382 . WASHER, BELLEVILLE - 1/4' 4
4-25 32035495 3203551 1 . SCREW, FILLISTER HEAD - 114 - 20 4
4-26 30221170 30221170 . VALVE, FINGER 4
4-27 37127289 37127297 . SPACER PLATE ,1
4-28 32267544 32267528 GASKET, SPACER 2

4-29 95053567 95053557 CAPSCREW -HEX112- 13 X 1 -.I/4' 8
4-30 9567 4701 9567 4701 GASKET, COPPER - 1/2' B
371 28535 37128576 CYLINDER

2
30289870 30294201 GASKEI, CYLINDER FLANGE 2
32194151 32'198376 SET, RING 2
3021 s263 30287825 PISTON, AIR - COMPLETE 2
30298020 30287791 . RING, LOCK 2
27
a
UJ
E.
o
a
a
trJ
O
O
(,
f o
J
(L z
J
J
L IJ
J
6 E,
o
o-
=-
o
J
=
f
hJ C)
lrJ
_)
J
d
o
)= UJ
E.
f
(,
L.
28
SR. PART UNITS SPARE
NO. NUMBER DESCRIPTION PER
ASSY. 1 2 3
MODEL V235A/235T PACKAGE
1 97044929 BASE PLATE '1
2 97044101 SLIDE RAIL 12' 1
3 70234943 BELT GUARD 1
4 97042295 DISTANCE PIECE BELT GUARD 112X5-5IB 2

6 70243761 MOTOR ELECTRIC 2 HP ANY MAKE TEFC 1
6 97044226 BELTV A- 68 '1
7 970437 49 PULLEY MOTOR 1
8 9705 1 643 SCRUBBER TANK 1

o
97053607 STARTER 2 HP DOL ANY MAKE 1
10 97050702 VACUUM SWIICH 1
MODEL V244N244T PACKAGE
'1
97044937 BASE PLATE 1
2 9i0441 01 SLIDE RAIL 12' 1
3 70236328 BELT GUARD .l
4 97042329 DISTANCE PIECE BELT GUARD 1t2xS-5tB 2

5 97088538 MOTOR ELECTRIC 2 HP ANY MAKE TEFC
1
6 97044283 BELTV A-78

2
7 97043582 PULLEY MOTOR
1
1
8 97051 650 SCRUBBER TANK 1
I 97053607 STARTER 2HP DOL ANY MAKE

1
10 97050702 VACUUM SWITCH
1
MODEL V255N255T PACKAGE
1 70236260 BASE PLATE

2 97044127 SLIDE RAIL 14' 'l
3 70235114 BELI GUARD

1
4 97042329 DISTANCE PIECE BELT GUARD 112X5 - 518 2

5 97055800 MOTOR ELECTRIC 5HP ANY MAKE TEFC
1
6 90235409 BELI V A-82
1
B 97051 668 SCRUBBER TANK 1

o
97053623 STARTER 5HP DOL ANY MAK
10 97050702 VACUUM SWITCH
29
COST SAVINGS KITS
For your convenience the following parts and / or spare parts
for your vaculrm pump are available rn parts kits.
When ordering the kits below, use kit name as Description and the parl
No. as shown
PABT
NUMBER DESCRIPTION QTY.
371 23650 TUNE UP KIT FOR MODEL V235 IV2g5T

Ref.
9501 81 49 . "O" RING 7lB X 1 - ll9 X 1lB 1
30420335 . GASKET SET 1
32194276 . RING PISTON SET LP 2
30221170 tM . VALVE H.P. 4
321 58883 . SEAL OIL 1
30420335 GASKET SET FOR V235 I V235

30299226 . GASKET CRANK CASE COVER 1
30295034 . GASKET COVER SHAFT END 1
30280499 . GASKET SPACER LP 2
32232761 . GASKET HEAD HP 1/16" THICK 2
30294912 . GASKET MANIFOLD 4
30294227 . GASKET FLNG. CYL. 2
371 23668 TUNE UP KIT FOR MODEL V244 I V244 T

Ref.
32194151 . RING PISTON SET 4'' HP 2
30420392 . GASKET SET 'l
30221170 tM . VALVE H.P. o
9501 81 49 . ,O'RING 7/8 X llB X 1lB' 1
321 58891 . SEAL OIL 'l
30420392 GASKET SET FOR V244 Bef.

3043931 9 . GASKET COVER CRANK CASE 1
32267551 . GASKET A/H - SPACER 4' GRAFKOTE 2
32267544 . GASKET CYL. - SPACER 4 ' GRAFKOTE L
30294854 . GASKET MANIFOLD CONNECTION 4
30289870 . GASKET FLYG. CYL. Z
37123676 TUNE UP KIT FOB MODEL V255 I V255 T Ref.

9501 B1 49 . 'o' RINF 7lB Z 1 - 1/B X 1/8" 1
30420442 . GASKET KIT FOR 1
321 58909 . SEAL OIL FOR 1
30221170 lM . VALVE H.P. B
321 98376 . RING PISTON SET LP - 5" DIA. 2
30420442 GASKET SET FOR V255 Ref.
30439327 . GASKET COVER CRANK CASE 1
32267536 tM . GASKET A/H 5'' 32267536 IM 2
32267528 tM . GASKET fuH 5'32267536 IM 2
30294854 . GASKET MANIFOLD CONNECTION 4
30294201 . GASKET FLNG. CYL. 2
30
MODEL - V235
coMPLETE OVERHAUL KtT (V 235)
SR. No. ccNc DESCRIPTION OTY.
371 23650AS01 Complete Overhaul Kit (V235) Ref.

1 30295034 Gasket Shaft End Cover 1
2 30299226 Gasket Frame Cover

3 30294227 Gasket Cylinder Flanqe 2
4 9501 B1 49 O Rino Oil Filler
5 321 58BB3 Oil Seal 1
r) 30221170 M Valve Finger lnleVDischarge 4

7 321 39891 Shims Flnger Valve 2
8 94467396 Piston Ring Set 1
I 32232761 Gasket Air Head 2

10 30280499 Gasket Spacer LP 2
11 30294912 Gasket Manifold 4
VALVE GASKET KrT (V235)
371 27650AS02 Valve Gasket Kit (V235) Ref

1 30221170 M Valve Finqer 4
L) 32232761 Gasket Air Head LP 2
4 321 39891 Shims Finqer Valve 2
CRANK CASE OVERHAUL KtT (V235)

SR. No. ccNc DESCR!PTION QTY.
371 23650AS03 Crank Case Overhaul Kit (V235) Ref .
1 3028981 3 Brush Crank Pin 1
J 30299226 Gasket Frame Cover 1
4 30294227 Gasket Cylinder Flanqe Z

5 9501 81 49 O Rino Oil Filler 1
r) 321 5BBB3 Oil Seal 1
AtR END OVERHAUL KtT (V235)

SB. No. ccNc DESCRIPTION OTY.
371 23550AS04 Air End Overhaul Kit (V235) Hef .
1 30221170 M Valve Finqer lnlet/Discharqe 4

2 3213989'l Shims Finoer Valve 2
3 94467396 Piston Rinq Sel 1
4 30294227 Gasket Cylinder Flange 2

5 32232761 Gasket Air Head 2
7 30294912 Gasket Manifold 4
31
MODEL . V244
CoMPLETE OVEBHAUL KtT (V 244)
371 23668AS01 Complete Overhaul Kit ru244)

'1
30294995 Gasket Shaft End Cover 1
2 3043931 I Gasket Frame Cover 1
3 30289870 Gasket Cvlinder Flanoe 2

4 9501 81 49 O Rina Oil trillar 1
5 321 58891 Oil Seal

6 30294854 Gasket Manifold Conn. 4
7 30221170 M Valve Finger I
B 32267551 M Gasket Air Head LP 2
I 32267544 M Gasket Spacer LP 2
10 94467404 Piston Rinq Set 1
'11
30294854 Gasket Manifold Conn. 4
VALVE GASKET KtT (V244)

371 23658AS02 Valve Gasket Kit (V244)

1 30221170 M Valve Finger 8
2 32267551 M Gasket Air Head LP 2
3 32267544 M Gasket Spacer LP 2
CRANK CASE OVERHAUL KrT (V244)

37123668AS03 Crank Case Overhaul Kit (V244)

1 3021 01 99 Brush Crank Pin 1
3 3043q31 I Gasket Frame Cover

4 30289870 Gasket Cvlinder Flanoe 2
5 9501 B1 49 O Rinq Oil Filler 1
6 32'158891 Oil Seal 1
30294854 Gasket Manifold Conn. 4
AIR END OVERHAUL KIT v244

SR. No. ccNc OESCRlPTION QTY.
371 23668AS04 Air End Overhaul Kit (V244)

1 30221170 M Valve Finger o
2 32267551 M Gasket Air Head LP 2
J 32267544 M Gasket Spacer LP 2
4 94467404 Piston Rino Set 1
32
MODEL. V255
CoMPLETE OVERHAUL KtT (V 255)
SR, No. ccNc DESCRIPTION trv.

37123676AS01 Complete Overhaul Kit (V255)
2 30439327 Gasket Frame Cover 1
3 30294201 Sasket Cylinder Flange 2

4 9501 B1 49 C Ring Oil Filler 1
5 321 58909 3il Seal 4

6 30221170 tM y'alve Finger
B
B 32267536 tM Gasket Air Head LP 2

I 32267528 tM Gasket Spacer LP 2
VALVE GASKET KtT (V255)
SR. No. ccNc )ESCRIPTION OTY.
37123676AS02 /alve Gasket Kit (V255)

1 30221170 M /alve Finger 8
2 32267536 M Sasket Air Head LP 2
3 62267528 M fasket Spacer LP 2
CRANK CASE OVERHAUL KtT (V255)

SR. No. ccNc DESCRIPTION OTY,
371 23675AS03 Crank Case Overhaul Kit (V255)

1 3021 01 65 Brush Crank Pin 1
3 30439327 Gasket Frame Cover 1

6 950'18149 O Ring Oil Filler 1
32 1 58909 i.Jtt Seal 4
ArR END OVERHAUL KtT (V255)

37123650AS04 Air End Overhaut Kit (V235) Ref.
1 30221170 M Valve Finger B
3 32267536 M Gasket Air Head Lp 2

4 32267528 M Gasket Spacer LP 2
33
Date 11.06.2018
DnD 150 DC13
Rev 00
Pump DnD 150
P a g e | 69
DnD-07
WIRING DIAGRAM
PT.KSB INDONESIA
PT.KSB INDONESIA
PT.KSB INDONESIA
PT.KSB INDONESIA
PT.KSB INDONESIA
PT.KSB INDONESIA
Date 11.06.2018
DnD 150 DC13
Rev 00
Pump DnD 150
P a g e | 70
DnD-08
SWING-CHECK
VALVE
•Operating Instructions
•Installation instructions for partly completed machinery
0570.821/20-10 - ORIGINAL
Diaphragm
Valves
with Handwheel and
Pneumatic Actuators
SISTO-KB/ -KBS
SISTO-10/ -10S/ -10M
SISTO-16RGA
SISTO-16TWA / HWA / DLU
SISTO-16 /-16S
SISTO-20/ -20M/ -20TWC
SISTO-B
SISTO-C
Check Valves
KRV
RSK / RSKS
Pneumatic actuators
Piston Actuated LAP
Diaphragm Actuated LAD
1. Declaration of conformity........................................................................................................................................ 2
2. Safety ........................................................................................................................................................................ 3
2.1 Marking of instructions in the operating instructions/installation instructions for partly completed machinery................... 3
2.2 Non-compliance with safety instructions......................................................................................................... 3
2.3 Safety awareness........................................................................................................................................... 3
2.4 Safety instructions for the operator / user....................................................................................................... 3
2.5 Safety instructions for maintenance, inspection and installation work............................................................ 3
2.6 Unauthorized modification and manufacture of spare parts........................................................................... 3
2.7 Unauthorized modes of operation................................................................................................................... 3
3. General instructions................................................................................................................................................ 3
4. Transport and storage............................................................................................................................................. 4
4.1 Corrosion protection....................................................................................................................................... 4
4.2 Transport......................................................................................................................................................... 4
4.3 Storage........................................................................................................................................................... 4
5. Description of the valves and pneumatic actuators............................................................................................. 4
5.1 Marking........................................................................................................................................................... 4
5.2 Drawings / Documentation.............................................................................................................................. 5
5.3 List of components.......................................................................................................................................... 8
5.4 Function.......................................................................................................................................................... 9
6. Installation................................................................................................................................................................ 9
6.1 General........................................................................................................................................................... 9
6.2 Installation position....................................................................................................................................... 10
6.3 Installation instructions................................................................................................................................. 10
6.4 Valves with actuator and pneumatic actuators on external valves............................................................... 10
6.5 Insulation...................................................................................................................................................... 10
7. Commissioning / Start-up / Shutdown................................................................................................................. 10
7.1 Commissioning / start-up.............................................................................................................................. 10
7.2 Shutdown...................................................................................................................................................... 13
8. Servicing / Maintenance........................................................................................................................................ 13
8.1 Safety instructions........................................................................................................................................ 13
8.2 Maintenance................................................................................................................................................. 13
8.3 Replacing the diaphragm.............................................................................................................................. 14
8.4 Replacing the valve disc............................................................................................................................... 16
8.5 Replacing the ball......................................................................................................................................... 16
8.6 Valve reassembly.......................................................................................................................................... 16
9. Trouble-shooting.................................................................................................................................................... 16
9.1 General......................................................................................................................................................... 16
9.2 Faults / Remedies......................................................................................................................................... 16
10. Tightening torques................................................................................................................................................. 17
11. Addition of the operating instructions which corresponds to the 94/9/EC Directive (ATEX100)................... 20
3
2. Safety 2.4 Safety instructions for the operator / user

The valves are intended for use in areas which cannot be accessed
These operating instructions/installation instructions for partly com- by unauthorised persons. Operation of the valves in areas which
pleted machinery contain important information which must be ob- can be accessed by unauthorised persons is only permitted if ap-
served during installation, operation and maintenance. propriate protective devices are fitted at the site. This is the respon-
sibility of the integrator or operator.
Not only must the general safety instructions laid down in this chap- Any hot or cold valve components (e. g. body components or hand-
ter on “Safety” be complied with, but also the safety instructions wheel) that could pose a hazard must be equipped with a guard by
outlined under specific headings. the operator.
Guards which are fitted to prevent accidental contact with moving
2.1 Marking of instructions in the operating instructions/ parts (e.g. coupling) must not be removed whilst the unit is opera-
ting.
installation instructions for partly completed machinery
Electrical hazards must be eliminated. (For details please refer to
The safety instructions contained in the operating instructions/in- VDE regulations and the safety regulations laid down by the local
stallation instructions for partly completed machinery whose non- energy supply companies, for instance).
observance might jeopardise the safety of persons, property and
the environment are specially marked with the general hazard sign, The operator needs to ensure that the guards for voltage-carrying
namely components are regularly checked for any damage. The valve must
never be operated without appropriate protection.
Standard SISTO diaphragm valves are designed in such a way
that any rupture of the diaphragm will be indicated by fluid handled
escaping from a leakage indication hole in the valve bonnet or from
the stem protection below the handwheel.
This must be taken into account when planning the system. Design
variants with re-pluggable leakage indication holes in fully sealed
valves can be agreed with the manufacturer.
Safety sign in accordance with DIN 4844 – W 9.
2.5 Safety instructions for maintenance, inspection and
The electrical danger warning sign is installation work
The operator is responsible for ensuring that all maintenance, in-
spection and installation work be performed by skilled and trained
personnel.
As a rule, work on actuated valves or on pneumatic actuators, must
only be carried out after the valve has cooled down and valve pres-
sure has been released. The fluid temperature must be below the
vaporization temperature limit in all areas in contact with the fluid.
Safety sign in accordance with DIN 4844 – W 8. Work on (actuated) valves or pneumatic actuators must only be car-
ried out during standstill. The shutdown procedure described in the
The word operating instructions/installation instructions for partly completed
machinery must be adhered to without fail.
CAUTION Immediately following completion of the work, all safety-relevant
and protective devices must be re-installed and / or re-activated.
is used to introduce safety instructions whose non-observance
may lead to damage to the valve or the pneumatic actuator and its Please observe all instructions set out in section 7 “Commissioning
functions. / Start-up” before returning the valve to service.
2.6 Unauthorized modification and manufacture of spare parts
Instructions attached directly to the valve or the pneumatic actuator
(e. g. nominal pressure) must always be complied with and be kept Modifications or alterations of the valve or the pneumatic actuator
in a perfectly legible condition at all times. supplied are only permitted after consultation with the manufacturer.
Original spare parts and accessories authorized by the manufactu-
rer ensure safety. The use of other parts can invalidate any liability
2.2 Non-compliance with safety instructions of the manufacturer for consequential damage.
2.7 Unauthorized modes of operation
Non-compliance with safety instructions can jeopardize the safety of
personnel, the environment and the valve or the pneumatic actuator The warranty relating to the operating reliability and safety of the
itself. Non-compliance with these safety instructions will also lead to valve und the pneumatic actuator supplied is only valid if the equip-
forfeiture of any and all rights to claims for damages. ment is used in accordance with its designated use as described in
section 3 “General instructions” of this manual.
In particular, non-compliance can, for example, result in: The limits stated in the technical literature must not be exceeded
under any circumstances.
- failure of important valve or pneumatic actuator / system func-
tions, 3. General instructions
- failure of prescribed maintenance and servicing practices,
- hazard to persons by electrical, mechanical and chemical ef- These operating instructions/installation instructions for partly
fects, completed machinery apply to all diaphragm valves, pneumatic
- hazard to the environment due to leakage of hazardous sub-
stances actuators and check valves of SISTO Armaturen S.A. as described
in section 5, unless reference is made to other operating manuals in
individual cases.
2.3 Safety awareness
Only correct installation, maintenance or repair will ensure smooth
operation of the valves and pneumatic actuators.
It is imperative to comply with the safety instructions contained in
this manual, the relevant national health and safety regulations and The manufacturer shall not accept any liability if the instructions set
the operator’s own internal work, operation and safety regulations. forth in this manual are not complied with.
4
4. Transport and storage

The design, manufacture and testing of SISTO Armaturen S.A.
valves are subject to a QM system to DIN EN ISO 9001 as well as The valves and pneumatic actuators are ready for operation upon
the European Pressure Equipment Directive 97/23/EC and the Ma- delivery. The line connection ports are closed with suitable material
chinery Directive 2006/42/EC, if applicable. Compliance with these (caps, plugs, covers).
requirements is based on normal, static loading, e.g.
4.1 Corrosion protection
As a standard, all valves and linear actuated pistons made of mate-
- flow velocities typical of the fluid handled rial not resistant to corrosion are painted with a primer which offers
- typical temperature gradients adequate corrosion protection under ambient atmosphere conditi-
ons normally encountered in buildings.
Valves manufactured by SISTO Armaturen S.A. are not designed If the valves are used in a corrosion-inducing atmosphere, the user
for use in systems with instable fluids. must apply a protective coating on site.
All valves with PTFE, TFM or PFA lining are corrosion-protected to
Others than normal operating conditions (temperature, pressure, category C3-M in accordance with DIN EN ISO 12944.
corrosive, chemical or abrasive influences) must be specified fully
and clearly in the purchase order, so that the valve manufacturer 4.2 Transport
can prepare and suggest suitable measures. Suitable precautions shall be taken to prevent damage during trans-
Such measures may, for example, influence port.
Ensure sufficient stability. Use transporting and moving equipment

- material selection which complies with the standards.
- wall thickness
- variants. CAUTION The valves must never be suspended by the
handwheel or by the actuator, if any, except linear actuated pistons
CAUTION with ring bolts.
The valves and pneumatic actuators must not be operated beyond
the permissible application range. The limit values are specified on For transporting large valves, ropes shall be attached to the yoke
the valve’s name plate or the valid type leaflet. Above all, the values arms or to the bolted bonnet/cover.
given in the pressure-temperature tables must not be exceeded. Valves with actuators shall be transported by means of ropes at-
Operation of the valves and pneumatic actuators outside the above- tached to the piping flanges, taking into account the centre of grav-
mentioned conditions may result in overloads which, in turn, may ity.
damage the valves and the actuators.
Use any lifting lugs provided.
Non-observance of this warning may cause personal For the valve or pneumatic actuator weights refer to the relevant
injury and damage to property, for example: manufacturer documentation (type leaflet - section 5.2).
- injuries resulting from fluid leakage (cold/hot, toxic, under pres After delivery and prior to installation, check the valve or the pneu-
sure, . . ), matic actuator for potential damage acquired in transit.
- impairment of the valve’s or pneumatic actuator’s function or its
destruction. 4.3 Storage
Storage / interim storage of the valves or pneumatic actuators must
The descriptions and instructions set forth in the operating instruc- ensure that even after a prolonged period of storage the valves’ or
tions/installation instructions for partly completed machinery refer to pneumatic actuators’ function is not impaired. The following require-
the standard models but are also applicable to variants. ments must be met:
For actuated valves with supplied actuators of external suppliers, - Storage is performed with the valve in the closed position (to
the operating manual of the actuator must be adhered to without protect the sealing surfaces against damage),
fail. - Measures are taken to protect the valves against dirt, humidity,
frost and corrosion (e.g. by using foils or caps; storage in dry
The operating instructions/installation instructions for partly comple- rooms).
ted machinery do not take into account:
5. Description of the valves and pneumatic
- any eventualities and events which might occur during installati
on, operation and maintenance, actuators
- local safety regulations; the operator must ensure that such re 5.1 Marking
gulations are strictly observed by all, including the personnel 5.1.1 Marking of the valves
called in for installation. The valves are marked in accordance with the Pressure Equipment
Directive 97/23/EC and the pertinent standards on valve types/de-
CAUTION sign, as well as TRD 110 (German Steam Boiler Regulations) and
The valve or pneumatic actuator must only be operated by skilled, TRB 801 No. 45 (German Pressure Vessel Regulations).
competent personnel.
Marking includes as a minimum:
Incorrect operation of the valve or of the pneumatic actuator may - manufacturer
have a substantial impact on the entire system, for example: - year of construction
- leakage of the fluid handled, - type or order no.
- DN
- system / machine brought to a standstill - PN or max. permissible pressure/temperature
- impairment / reduction / increase of the system’s / machine’s - material
function / effect.
The CE marking on the valve indicates that it is in conformity with
For any queries you may have or in the case of damage, please the European Pressure Equipment Directive 97/23/EC.
contact the manufacturer.
5.1.2 Marking of the pneumatic actuators
For any queries and repeat orders, in particular for purchasing spa- Type plate with:
re parts, please specify the type series / variant details, the order - name of series
number, as well as the year of construction, if possible. - size of actuator, spring, stroke
- Pmax (max. air supply pressure)
The technical data (operating data) of the valves or of the pneuma- - Ident. no.
tic actuators is specified in the technical literature (type leaflet, valve
characteristic, chemical resistance chart) of the concerned valve or Type
the concerned pneumatic actuator (cf. section 5). Kolben ∅
PSt max (bar) Dat.
CAUTION The operating instructions/installation instructions for
partly completed machinery must be kept for the entire life cycle of Code
the equipment. A KSB company •
Actuators with preloaded springs must be equipped with a danger

When assembling components of various manufacturers, sign: „Danger, loaded spring do not disassemble“.
the manuals of the individual components must also be complied
DANGER ACHTUNG
with. loaded spring vorgespannte Feder
do not disDVsemble nicht demontieren
5.2 Drawings / Documentation

The sectional drawings below provide examples of the general design / configuration of the valves and pneumatic actuators. For illustrations
relating to specific valve series and further information please refer to the respective type leaflets.
5.2.1 Diaphragm valves with handwheel for industry and building services
Type DN PN Material Type series booklet No.*)

SISTO-KB 015-200 10 as specified in the type series booklet 8651.1
SISTO-KBS 015-200 / ND ½“-8“ 10 as specified in the type series booklet 8651.101
SISTO-10 015-300 10 as specified in the type series booklet 8641.1
SISTO-10S 015-200 / ND ½“-8“ 10 as specified in the type series booklet 8641.101
SISTO-10M Rp ½“-3“ 10 as specified in the type series booklet 8641.102
SISTO-16TWA / HWA / DLU 015-200 16 as specified in the type series booklet 8635.33
SISTO-16S 015-200 / ND ¾“-8“ 16 as specified in the type series booklet 8635.101
SISTO-20M 010-050 16 as specified in the type series booklet 8638.12
Rp 3/8“ - 2“
SISTO-16RGA 015-080 16 as specified in the type series booklet 8638.1
Rp ½“-3“
SISTO-20TWC 015-200 16 as specified in the type series booklet 8638.120
Sectional drawings
544
902
920.1
SISTO-KB
SISTO-KB Model DN 125-200
Model DN 015-100 as a variant DN 015-100
961 920.2
621.1 554
621.2 550.2
200 550.1
553 920.1
165
443
901/902+920.3
100
SISTO-10/ -10S
SISTO-10 socket
920
550.2
961
621.1
200
165
553
901.2
951
901.1
550.1
443
100
SISTO-16TWA/HWA/DLU SISTO-20M
SISTO-16/-16S
SISTO-20/ SISTO-20TWC SISTO-16 RGA
*) Available for download at www.sisto.lu

6
5.2.2. Diaphragm valves with pneumatic diaphragm actuator for industry and building services resp. pneumatic
actuator without valve
Type DN PN Material Type series booklet No. *)

SISTO-KB/-KBS 015-100 10 as specified in the type series booklet 8651.1/ 8651.101
SISTO-10/-10S/-10M 015-125 10 as specified in the type series booklet 8641.1/ 8641.101
SISTO-16/-16S/-20 015-125 16 as specified in the type series booklet 8635.1/ 8635.101/ 8643.1
Sectional drawings
920.7 920.4
920.4 412.2*
412.2 202
151.2
547 950 911
151.2 550 443.1
443.1*
901.1
412.1
412.1* 202 412.1
412.1*
920.3
550 840 151.1 950
901.1 920.6
920.6 443.1
200
443.1*
920.3 151.3
151.1 911
911 SISTO-LAD-OF
165 920.4
412.2
412.2* 901 920.7
443
443*
553 202
100
920 412.2
412.2*
151.2
911
550
901.1
443.1
443.1* 920.3
412.1
412.1*
920.6 151.1
SISTO diaphragm valve with 200
mounted SISTO-LAD-SF 151.3
SISTO-LAD-AZ
5.2.3. Diaphragm valves with pneumatic piston actuator for industry and building services resp. linear actuated pistons
without valve

SISTO-KB/-KBS 015-200 10 as specified in the type series booklet 8651.1 / 86501.101
SISTO-10/-10S/-10M 015-300 10 as specified in the type series booklet 8641.1 / 8641.101
SISTO-16/-16S/-20 015-200 16 as specified in the type series booklet 8635.1 / 8635.101/ 8643.1
SISTO-LAP as specified in the type series booklet 9210.1
Sectional drawings
901.2 160
901.3
400
400*
920.12
543
412.4
412.4* 595*
141 412.5
412.5*
310 176
400
400* 410
410*
920.11
932
902.1 209
500 920.9
920.10
SISTO-LAP-AZ
901.3 160
914
547
209.2
543
141
595
595* 950
412.4
412.4*
412.5
412.5* 310
400 176
410
410*
920.11 932
902.1 209.1
500 920.9
920.10
SISTO-LAP-SF
SISTO diaphragm valve with
mounted SISTO-LAP-OF

7
5.2.4. Diaphragm valves with handwheel or pneumatic actuator for sterile processes

SISTO-B 006-100 10 as specified in the type series booklet 8646.1
SISTO-C 006-100 16 as specified in the type series booklet 8644.1
Sectional drawings
SISTO-B with handwheel 920.3

920.2 412.1
544 961.1 961.2 554 961.2 580
160 544 562
961.1 932
940
160 961.1 550.3 550.5
840.1 550.2 310.2
412.1 412.2 200.1 840.1 314
514.1 165.1 412.2 200.1 621.1 840.2
915 165.1 621.2 514.2
200.3 915 904
412.1 562 412.1 550.2
553.1 562 200.2 902 + 200.1
550.1
165.1 901 553.1 553.2 920.3 553.1
914 554 901 165.2 920.1
5 554
554 165.1 923
920.2 443
443* 901 951.1 951.2
554 100
100 443
443* /902+920.3 443
443*
562 443
443*
553.1 554
443
443*
100
100 100
SISTO-B DN 06-10 SISTO-B DN 15-25 SISTO-B DN 32-50 SISTO-B DN 65-080 SISTO-B DN 100
685
SISTO-B with mounted LAP-SF 920.4 547.2
920.3
920.1 950.2
547.1 621 547.1 160
160 578 209 202
950.1
920.1 950.2 840
554 920.1
595
595* 176 412.2
412.1
412.1* 920.1 151.2 913
595
595* 920.1 412.2 932 901.2
443.2
443.2*
554 562 901.1 920.1
412.1 550
209 412.1* 911
553.1 554 920.3
553.2
176 901.1 443.1
443.1* 165.1 151.1 200
412.2 554
443.1 100
443.1* 165.1 553.2
100 412.3 412.1
412.1* 920.1
915 165.2 443.1
443.1*
100
901.1/902+
920.2 951
554
SISTO-B LAP-SF DN 06-10 SISTO-B LAP-SF DN 15-50 SISTO-B LAD-SF DN 65-100

Air supply pressure 5-7 bar Air supply pressure 5-7 bar Air supply pressure 4-6 bar
SISTO-C with handwheel 544

160 961.2
920
554
932
961.1 961.1 160
160 840 961.1
412.1 200.2
544 412.2 412.4
514 165 621
915 550.2
200.1 840 412.3 562
412.2 550.1
553 915
200.3 920.1
165 901 553
165 554 915
914 200.1
901 951 165
901 951
553 915 901
915 553 443 443
443 100
554 443 554
100
100 100
SISTO-C DN 06-10 SISTO-C DN 15 SISTO-C DN 25-32 SISTO-C DN 40-100
SISTO-C with mounted LAP-SF 547

578
950.1
578 950.2
950.1
547 160
578 202
621 209.2
547
547 621 920.1 950.2
160 950.1
160 554 920
950.1
595 176
412 920.1
165
209.1 932
595
553 562 901 412
595 920.1 209.1
554 553 554
901 554 553
209 553 443 165
901 412 915 901
176 165 100 412.3 443
412 554 915
443 165 100 443 100
100
SISTO-C LAP-SF DN 06 - 10 SISTO-C LAP-SF DN 15-20 SISTO-C LAP-SF DN 25-50 SISTO-C LAP-SF DN 65-100

8
5.2.5. Check valves for industry and building services
Type DN PN Material Type series booklet No.

KRV 020-200 10 as specified in the type series booklet 8671.1
RSK/RSKS 025-300 16 as specified in the type series booklet 8675.1
Sectional drawings 100 411.2

411.2* 746
746* 160 901
900.2
101
411.1
411.1*
102
486
486*
901
KRV RSK/RSKS
5.3 List of components
Part No. Description Part No. Description
100 Body 550.4 Disc

101 Upper body 550.5 Disc
102 Lower body 553 Compressor
141 Cylinder 553.1 Compressor
151.1 Lower cover 553.2 Compressor
152.2 Upper cover 554 Washer
153.3 Upper cover with ISO-coupling flange 562 Paralell pin
160 Screw cap 578 Spring guiding
165 Bonnet 580 cap nut
165.1 Bonnet 595* Piston
165.2 Bonnet 621 Opening indicator
168 Yoke 621.1 Upper opening indicator
172 Bonnet with yoke 621.2 Lower Opening indicator
176 Bottom plate 685 Protection against contact
200 Stem 746* Valve disc
200.1 Stem 840 Coupling
200.2 Stem 840.1 Adaptor
200.3 Stem 840.2 Adaptor
202 Thrust stem 901 Hexagon head bolt
209 Piston rod 901.1 Hexagon head bolt
209.1 Lower piston rod 901.2 Hexagon head bolt
209.2 Uppter piston rod 901.3 Hexagon head bolt
310 Sliding bush 902 Stud
310.1 Sliding bush 902.1 Stud
310.2 Sliding bush 904 Threaded pin
314 Axial bearing 911 Air supply port
400 Gasket 913 Air rent screw
410 Sealing strip 914 Cylinder head screw
411.1* Joint ring 915 Discharge screw
411.2* Joint ring 920 Hexagon nut
412.1* O-Ring 920.1 Hexagon nut
412.5* O-Ring 920.5 Square nut
443* Diaphragm 920.7 Hexagon nut
443.1* Diaphragm 920.8 Hexagon nut
443.2* Actuator diaphragm 920.9 Hexagon nut
486* Ball 920.10 Hexagon nut
500 Lock washer 920.11 Hexagon nut
514 Threaded disc 920.12 Hexagon nut
514.1 Threaded disc 923 Bearing nut
514.2 Threaded disc 932 Retaining ring
519 Position indicator 940 Parallel key
543 Spacer bush 950 Spring
544 Threaded bush 950.1 Spring
547 Guide bush 950.2 Spring
547.1 Guide bush 951 Support spring
547.2 Guide bush 951.1 Support spring
550 Disc 951.2 Support spring
550.1 Disc 961.1 Handwheel
550.2 Disc 961.2 Handwheel
550.3 Disc
* Recommended spare parts

9
5.4 Function The valves/actuators are automatically taken to their fail-safe positions
5.4.1 Diaphragm valves with handwheel for industry and as soon as the control air is intentionally or unintentionally released.
building services The visible moving parts of the valve (both manual and automatic
actuation) also serve as position indicators for the valve
The valves consist of the pressure-retaining parts, i.e. body (100)
and bonnet (165), and the functional unit. Diaphragm valves for sterile process are either of the SISTO-C
and SISTO-B type.
The body (100) and bonnet (165) are connected by hexagon head
bolts (901) or studs (902) and nuts (920.2). The valves consist of the pressure-retaining parts, i.e. body (100) and
bonnet (165), and the functional unit. The body (100) and actuator
The functional unit consists of bonnet (165), handwheel (961), or bonnet (165) are connected by hexagon head bolts (901). The
stem (200), compressor (553) with square nut (920) and diaphragm functional unit of diaphragm valves with handwheel consists of bonnet
(443). (165), handwheel (961), stem (200), compressor (553) and diaphragm
(443).
5.4.2 Diaphragm valves with pneumatic diaphragm
actuator for industry and building services resp. The functional unit of SISTO-B diaphragm valves with pneumatic
actuator consists of the pneumatic piston actuator (SF, OF+AZ). The
pneumatic actuators without valves piston actuator consists of bonnet with G 1/8”- pilot air supply con-
Diaphragm valves with pneumatic diaphragm actuator and/or pneu- nection (DIN ISO 228-1) (165), compressor (553), piston rod (209),
matic diaphragm actuators without valves are available in spring to bottom flange (176), cover (160), piston (595), spring (950), spring
close (SF), spring to open (OF) and double-acting (AZ) design. guiding (578) and diaphragm (443).
5.4.5 Check valves for industry and building services

The valves/actuators are automatically taken to their Check valves for industry and building services are either of the disc
fail-safe positions as soon as the control air is intentionally or un- or ball type.
intentionally released. The visible moving parts of the valve (both
manual and automatic actuation) also serve as position indicators The RSK/RSKS swing check valve consists of body (100), cover
for the valve. (160), joint ring (411.2) and valve disc (746). Cover (160) and body
The valves/actuators are automatically taken to their fail-safe posi- (100) are connected by hexagon head bolts (901). The upper end of
tions as soon as the control air is intentionally or unintentionally the valve disc (746) is tightly clamped between cover (160) and body
released. The visible moving parts of the valve (both manual and (100) allowing the lower end to move freely in the swing check valve’s
automatic actuation) also serve as position indicators for the valve. flow path. This ensures that the valve disc (746) is pressed against
the seat in one direction, preventing throughflow.
The valves consist of the pressure-retaining parts, i.e. body (100)
and bonnet (165), and the functional unit. The KRV ball non-return valve consists of upper body (101), lower
The body (100) and actuator or bonnet (165) are connected by body (102) and ball (486). The upper body (101) and the lower body
hexagon head bolts (901) or studs (902) and hexagon nuts (920.2). (102) are connected by hexagon head bolts (901) and hexagon nuts
(920.2). The ball (486) is located between the upper body (101) and
The diaphragm actuator functional unit consists of bonnet (165), lower body (102). This ensures that the ball (486) is pressed against
actuator cases (151.1/151.2), actuator diaphragm (443.1) with dia- the seat in one direction, preventing throughflow. A joint ring (411.1)
phragm plate (550.3), spring (950) (for OF and SF designs), stem is placed between the upper body (101) and the lower body (102) to
(200), sliding stem (202), compressor (553) with square nut (920) effect sealing to atmosphere.
and diaphragm (443).
6. Installation
The diaphragm actuator functional unit consists of bonnet (165),
actuator cases (151.1/151.2), actuator diaphragm (443.1) with dia- 6.1 General
phragm plate (550.3), spring (950) (for OF and SF designs), stem
(200), sliding stem (202), compressor (553) with square nut (920) As a rule, the engineering contractor, construction company or opera-
and diaphragm (443). tor / user are responsible for the positioning and installation of the
valves or the pneumatic actuators.
5.4.3 Diaphragm valves with pneumatic piston actuator Planning and installation errors may impair the reliable function of
for industry and building services the valves or the pneumatic actuators and pose a substantial safety
Diaphragm valves with pneumatic diaphragm actuator and/or pneu- hazard. Compliance with the following requirements is of particular
matic diaphragm actuators without valves are available in spring to importance:
close (SF), spring to open (OF) and double-acting (AZ) design. CAUTION The piping must be laid such that detrimental
thrust and torsional forces are kept away from the valve bodies during
installation and operation to avoid impairment of valve function and/or
The valves/actuators are automatically taken to their valve rupture.
fail-safe positions as soon as the control air is intentionally or un-
intentionally released. The visible moving parts of the valve (both CAUTION The caps on the connection ports shall be re-
manual and automatic actuation) also serve as position indicators moved immediately prior to installation.
for the valve.
The valves/actuators are automatically taken to their fail-safe po- Do not paint any parts which are relevant to the function of the valve,
sitions as soon as the control air is intentionally or unintentionally such as moving stems and parts of the position indicator.
released. The visible moving parts of the valve (both manual and CAUTION The mating flanges of the flanged valves de-
automatic actuation) also serve as position indicators for the valve. scribed in this manual comply with flange standard EN1092-1 / -2,
Diaphragm valves with pneumatic piston actuator are available in incl. finish of sealing surfaces for elastomer or fluoroelastomer gas-
spring to close (SF), spring to open (OF) and double-acting (AZ) kets.
design.
The valves consist of the pressure-retaining parts, i.e. body (100) When painting the pipelines and valves, do not apply paint
and bonnet assembly (172), and the functional unit. to the bolts, stems and plastic components (valve function will be
The body (100) and actuator or bonnet assembly (172) are connec- impaired). If construction work is still in progress, the valves and the
ted by hexagon head bolts (901) or studs (902) and hexagon nuts pneumatic actuators must be protected against dust, sand and build-
(920.2). ing material (cover with suitable material).
The piston actuator functional unit consists of bonnet assembly Do not use valve handwheels as footholds.
(172), cylinder (141), piston (595), spring (950) (for OF and SF de-
signs), piston rod (209), sliding stem (202), compressor (553) with
square nut (920) and diaphragm (443). For safety reasons, valves and piping systems operated
The actuator piston unit without valve consists of the actuator bot- at high (> 50° C) or low (< 0° C) temperatures must be insulated, or a
tom plate (176) with ISO-coupling-flange, the cylinder (141), the warning sign must point out the risk of personal injury involved when
actuator cover plate (160), the piston with sealing ring (595), the touching the hot or cold components.
spring (950), the upper piston road (209) and the sliding stem (202). With reference to the EnEV (Energieeinsparverordnung) we recom-
mend to isolate those valves that are used for warm or hot medium
5.4.4 Diaphragm valves with handwheel or pneumatic flow, for the save of energy.
actuator for sterile processes The lifetime of plastic coated valves will be extended if the valves are
Diaphragm valves with pneumatic diaphragm actuator and/or pneu- isolated.
matic diaphragm actuators without valves are available in spring to Valves and pneumatic actuators with external moving elements must
close (SF), spring to open (OF) and double-acting (AZ) design. be fitted with protective covers, or other suitable measures must be
taken to prevent accidents.

The valves/actuators are automatically taken to their
fail-safe positions as soon as the control air is intentionally or un- Valves used as dead-end valves in a pipeline should be
intentionally released. The visible moving parts of the valve (both protected against unauthorized or unintentional opening, to prevent
manual and automatic actuation) also serve as position indicators damage to property and/or personal injury as well as environmental
for the valve. damage.
10
6.2 Installation position 6.4 Valves with actuator
The valve bodies are marked with an arrow indicating flow direction, Valves with transmission gear and/or actuators and pneumatic actua-
if necessary. The valves must be installed such that the flow directors on external valves must be installed with the stem in vertical
tion of the fluid corresponds to the direction shown by the arrow position, if possible. If this requirement cannot be met, adequately
cast on the valve body. If no directional arrow is cast on the valve support the actuator on site or consult the manufacturer.
body, the valve can be installed in any position.

6.2.1 Diaphragm valves Electrical connection shall be effected by suitably trained
personnel only.
Diaphragm valves can be installed in any position. However, the
best installation position is with the stem pointing vertically upwards. VDE 0100 and VDE 0165 (explosion protection) regulations must be
adhered to!
6.2.2 Check valves
All electrical equipment such as actuator, control panel, solenoid
RSK/RSKS swing check valves must always be installed such valve, limit switch, etc. must be installed in dry flood-proof rooms.
that the flow direction of the fluid corresponds to the direction shown
by the arrow cast on the cover (160). Voltage and frequency must correspond to the data on the name
KRV ball non-return valves must always be installed such that the plate.
flow direction of the fluid corresponds to the direction shown by the
arrow cast on the upper body (102). 6.5 Insulation
6.2.3 Special designs If the valve is to be insulated, make sure that the insulation does not
impair the function of the valve. SISTO Armaturen S.A. recommends
For the positioning and installation of special design valves, please to make sure that the sealing areas at the cover / bonnet joints and at
contact the engineering contractor, construction company or opera- the stem passage are easily accessible and visible.
tor / user.
7. Commissioning / Start-up / Shutdown
6.3 Installation instructions
(Please also refer to section 6 „Installation“)
6.3.1 Flanged valves
7.1 Commissioning / Start-up
The mating flange faces must be clean and undamaged.
7.1.1 General
The gaskets on the mating flanges must be properly
centred. Only connection and sealing elements made of approved Prior to commissioning / start-up compare the material, pressure and
materials shall be used. Valves with PTFE/TFM/PFA lining must temperature data on the valves with the operating conditions of the
not be used in combination with metallic seals. Valves with soft piping to check the material’s chemical resistance and stability under
rubber lining or PTFE/TFM/PFA lining can be used, for reason of load.
their material property, without any additional sealing. Precondition
is, that the counter-flanges used, are manufactured according the
same regulations/standards as the valves. For the flange connec- Surge pressure (water hammer), which might occur, must
tion between valve and pipe use all flange bolt holes provided. not exceed the max. permissible pressure. Safety measures are re-
quired to be taken by the operator / user.
Use suitable tools to tighten the bolts evenly and crosswise at the
permissible torques (see section 10). In new systems and particularly after repair, the complete piping
system must be thoroughly flushed with the valves fully opened so
that particles and / or welding beads that might damage the valve are
6.3.2 Welding instructions removed.
Responsibility for the welding of the valves into the piping and for The responsibility for the media and method used for cleaning the pip-
any heat treatment required, is with the executing contractor or the ing system lies with the party carrying out the cleaning.
operator of the facility.
CAUTION When welding valves with butt or socket weld Venting the valve by undoing the bonnet/cover bolting is
ends into the piping or when performing welding jobs on a pipeline dangerous and therefore not permitted. To prevent damage to the
after the valves have been installed (pipeline installation) make sure valve material or joint seals, the usual start-up and shutdown veloci-
that no contamination enters the valve body to prevent damage to ties must be adhered to.
the linings or diaphragms.
7.1.2 Valve actuation

CAUTION When welding the valve into the pipeline, take
special care, e.g. welding in several steps and at high welding Viewed from above, the manually actuated valve is closed with a
speed, so that the temperature rise in the middle of the valve body clock-wise turn of the handwheel, and opened with a counter clock-
does not exceed the max. permissible operating temperature. The wise turn. Valve variants which deviate from this rule are marked
bonnet including diaphragm must be dismantled prior to welding the accordingly.
valve body.
CAUTION Valves with handwheels may only be actuated by
hand. As the valve can be damaged by applying excessive forces, it is
CAUTION To prevent scorching, the welding cables must not allowed to use additional levers to move the handwheel.
not be attached to functional valve elements or valve surfaces that
have to meet specific roughness requirements. Shut-off valves are normally used in such a way that they are either
fully open or fully closed.
On valves with socket weld ends, the insertion depth given in the
applicable technical code must be complied with. A gap between the If, while opening or closing the valve, a resistance can be felt, the
pipe end and the socket base will prevent impermissible stresses in valve is in its final position and the operation must be stopped.
the weld.
11
7.1.3 Functional check prior to commissioning If the auxiliary energy supply fails, the actuator can be operated
manually by means of the emergency handwheel (961) mounted
Check the shut-off function of the installed valve prior to commis- on the pneumatic actuator (LAP).
sioning/start-up by opening and closing the valve several times.
If required, evenly re-tighten the cover/bonnet bolting as well as the In normal operation, the emergency handwheel is disengaged from
bolting at the mating flanges (see section 10). the pneumatic actuator. For the pneumatic actuator to be operated
via the emergency handwheel in emergencies, the two systems
SISTO Armaturen S.A. recommends the following functions to be must be connected with each other as described below.
checked: Turn the handwheel (961) in clockwise direction to position the up-
Check the shut-off function of the installed valves prior to commis- per stem (200) incl. coupling (485) on the upper piston rod (209).
sioning / start-up by opening and closing them several times. Connect the coupling (485) and the piston rod (209) with the spring
If required, evenly re-tighten the cover / bonnet bolting as well as cotter (933) supplied. As a result, the actuator can be moved to the
the bolting at the mating flanges. closed position by turning the handwheel (961) clockwise and to
CAUTION Open the valve by two full handwheel turns the open position by turning the handwheel anti-clockwise.
before re-tightening the cover / bonnet bolting to avoid stress or
distortion. NOTE Risk of system malfunction
7.1.4 Valves with actuator
Automatic operation of the pneumatic actuator with the manual
override engaged could result in valve damage and/or system
malfunction.
On valves with electric / pneumatic actuators, the strokes / actuating
forces must be limited.
NOTE Risk of system malfunction
Electric actuators are factory-set ready for operation. They shall be The spring cotter (933) must be removed before the actuator is
wired as follows:
returned to normal operation. Turn the handwheel (961) anti-clo-
ckwise until the stem (200) has been returned to its initial position.
Diaphragm valve “CLOSE” travel-dependent
Diaphragm valve “OPEN” travel-dependent
Finally, remove the spring cotter (933) and insert it into the bore
provided in the lantern (166) below the anti-rotation device fitted on
CAUTION Changing to force-dependent limit switching may re- the stem.
duce the service life of the diaphragm.
The wiring diagrams are given in the terminal boxes.

Manual override on spring-to-open actuators (LAP-OF):
For pneumatic actuators, the control pressures specified in the
order shall be complied with. Non-observance may damage the Drawing (example):
actuator.
Closing and opening torques or actuating forces shall be enquired

from the manufacturer, if necessary.
7.1.5 Manual override of pneumatically actuated valves by

fitted emergency handwheel in the event of auxiliary 200
energy failure
Manual override of double-acting actuators (LAP-AZ):
Drawing (example):
If the auxiliary energy supply fails, the actuator can be manually

operated in closing direction by means of the emergency hand-
wheel (961) mounted on the pneumatic actuator (LAP).
In normal operation, the emergency handwheel is without function.
To operate the pneumatic actuator via the emergency handwheel

in emergencies, proceed as follows:
Turn the handwheel (961) in clockwise direction. The stem (200)

will compress the spring pack via the piston (595), thus closing the
valve. The emergency handwheel cannot be used to actuate the
mechanically blocked valve.

Activating automatic operation of the pneumatic actuator before
having returned the manual override to its initial position could
result in valve damage and/or system malfunction.
Valve travel would be restricted, resulting in a reduced volume flow
through the valve.
12
NOTE Risk of system malfunction For actuating the emergency handwheel refer to the Section on
Before reactivating normal operation, turn the handwheel (961) anti-clo- „Manual override on double-acting actuators“.
ckwise to return the stem (200) to its initial position up to the stop.
To set the travel stop, loosen the nut (920) which locks the
Manual override on spring-to-close actuators (LAP-SF): locating sleeve (527) in position. The actuator must be in the
Drawing (example): „OPEN“ position. The travel stop in closing direction can now be
positioned as required by turning it clockwise. Now screw the nut
(920) down against the locating sleeve (527) and lock firmly.

Vibrations may result in the locked nut working loose. The travel
stop, therefore, needs to be checked regularly.

Manual override with travel stop in opening direction on
spring-to-open actuators (LAP-OF):

Drawing (example):

If the auxiliary energy supply fails, the actuator can be manually operated
in opening direction by means of the emergency handwheel (961) moun-
ted on the pneumatic actuator (LAP).
In normal operation, the emergency handwheel is without function. To

operate the pneumatic actuator via the emergency handwheel in emer-
gencies, proceed as follows:
Turn the handwheel (961) in anti-clockwise direction. The threaded bush

(544) will contract the spring pack via the upper piston rod (209), thus
opening the valve. The emergency handwheel cannot be used to close
the mechanically blocked valve.

Activating automatic operation of the pneumatic actuator before having
returned the manual override to its initial position could result in valve
damage and/or system malfunction.
Valve travel would be restricted, preventing the valve disc from reaching
the fully closed position and providing tight shut-off.

Before reactivating normal operation, turn the handwheel (961) clockwise
to return the threaded bush (544) to its initial position up to the stop.
Manual override with travel stop in closing direction on double-ac-

ting actuators (LAP-AZ):
Drawing (example):
For the emergency handwheel to be actuated, the two nuts (920)
must be loosened and screwed to the upper end position. Then
proceed as described in the Section on „Manual override on
spring-to-open actuators“.
To set the travel stop, first loosen the two nuts (920) and screw
them to the upper end position. The actuator must be in the
„CLOSED“ position. Then turn the handwheel in closing direction
until travel is restricted as required. Now screw the two nuts
(920) downwards up to the stop and lock firmly.

Vibrations may result in the locked nuts working loose. The
travel stop, therefore, needs to be checked regularly.
13
Manual override with travel stop in opening direction on

spring-to-close actuators (LAP-OF):
Danger of death when opening a valve under pressure!
Drawing (example): If toxic or easily inflammable fluids were handled, or fluids whose
residues may cause corrosion in conjunction with air humidity, drain
the valve and flush or vent it. If required, wear safety clothing and a
protective mask!
Depending on the installation position, fluid residues may be left in

the valve; these must be collected and properly disposed of.
Prior to any transport, flush and drain the valve thoroughly.
If you have any questions please contact the manufacturer.
For actuated valves, also observe the following additional in-

structions:

If actuators powered by an external source of energy
(electric, pneumatic) need to be removed from the valves or dis-
mantled, the energy supply must be shut down prior to starting any
work and the instructions in sections 3, 8.1.1 and the operating
manual of the actuator must be observed.
.

For the emergency handwheel to be actuated, the two locked nuts
Actuators with integrated spring mechanism contain pre-
loaded springs. They shall only be dismantled with extreme care,
(920) must be loosened (920) first. Then proceed as described in
using the requisite locking devices.
the Section on „Manual override on spring-to-close actuators“.
To set the travel stop, first loosen the two nuts (920) and screw If you have any questions please contact the manufacturer.
them to the upper end position. The actuator must be in the .
„CLOSED“ position. Then turn the handwheel in closing direction
until travel is restricted as required. Now screw the two nuts (920) 8.2 Maintenance
downwards up to the stop and lock firmly.
All valves and pneumatic actuators components have been de-
signed to be largely maintenance-free. The materials of the moving
NOTE Risk of system malfunction parts have been selected for minimum wear.
Vibrations may result in the locked nuts working loose. The travel
stop, therefore, needs to be checked regularly. On diaphragm valves, the diaphragm is the highest stressed com-
7.2 Shutdown ponent.
SISTO Armaturen S.A. recommends that, in the event of prolonged On RSK/RSK-S swing check valves, the valve disc is the highest
shutdowns, fluids which change their physical condition due to stressed component.
changes in concentration, polymerization, crystallization, solidifi- On KRV ball non-return valves, the ball is the highest stressed
cation, etc. must be drained from the piping. If required, flush the component.
piping with the valves fully opened.
The highest stressed components (diaphragm, valve disc, ball) are
not only subject to mechanical stress but also to wear caused by
8. Servicing / Maintenance the medium. We recommend to regularly check these wear parts at
intervals to be individually stipulated depending on service condi-
8.1 Safety instructions tions and actuation frequency.
Repair and maintenance work must only be performed by skilled, - For checking the diaphragm, remove the bonnet from the
competent personnel taking into account the relevant health and
body. See also section 8.3 „Replacing the diaphragm“.
safety regulations.
It is imperative that the below safety instructions and the general - For checking the valve disc, remove the cover from the
information on safety as per section 2 “Safety” be observed for all body. See also section 8.4 „Replacing the valve disc“.
servicing and maintenance work to be performed.
- For checking the ball, remove the upper body from the
CAUTION Always use suitable spare parts and tools, even lower body. See also section 8.5 „Replacing the ball“.
in emergencies, to ensure proper functioning of the valves or of the
pneumatic actuators.
We recommend to regularly check these wear parts at intervals to
8.1.1 Valve dismantling be individually stipulated depending on service conditions and ac-
tuation frequency and replace them if required.
Before removing the complete valve from the pipeline or before
repair or maintenance work to the valve itself, i.e. The operator/user is responsible for fixing appropriate inspection
and servicing intervals as required by the service conditions of the
- prior to undoing the flange bolting between valve and pipe valves and pneumatic actuators.
- prior to undoing the cover / bonnet bolting
- prior to removing any drain or vent plugs
- prior to removing a bolted actuator
Valve pressure must be released and the valve must be allowed to

cool down such that the temperature is below the fluid’s vaporiza-
tion temperature in all areas in contact with the fluid in order to
effectively prevent any risk of scalding.

14
The service life of valves and pneumatic actuators can be pro- 8.3.2 Replacing the diaphragm of diaphragm valves with
longed by: pneumatic diaphragm actuator for industry and
building services
- actuating the valve (open-close) at least once or twice a
year to check its function The valve bonnet can only be dismantled together with the
- lubricating the movable parts with standardised lubricants actuator. Spring to close (SF) actuators must be pressurized to open
to DIN 51825 which are suitable for the application of the the valve whereas on spring to open (OF) and double-acting (AZ)
valve. actuators the pressure must be released.
Undo hexagon head bolts (901) or stud (902) and hexagon nut
The safety instruction in sections 2 and 8.1 and the notes in section (920.2) to dismantle bonnet with actuator. Unscrew diaphragm (443)
9 shall be observed. from compressor (553) and square nut (920) by turning counter-clo-
ckwise. When fitting the replacement diaphragm refer to the material
8.3 Replacing the diaphragm marking on the diaphragm. Effect reassembly in reverse order. He-
xagon head bolts (901) must be evenly tightened crosswise.
8.3.1 Replacing the diaphragm of diaphragm valves with
handwheel Proceed as follows to fit the new diaphragm (443):

Undo hexagon head bolts (901) or studs (902) and • The contact surfaces of the diaphragm inside the body and the
hexagonnuts (920.2) to dismantle the bonnet. Unscrew diaphragm bonnet must be clean and dry.
(443) from compressor (553) and square nut (920) by turning it • Take the upper valve section (165) to the closed position (by
counter-clockwise. When fitting the replacement diaphragm refer to releasing the pressure of spring-to-close actuators, or - in the
the material marking on the diaphragm. case of double-acting actuators and spring-to-open actuators -
by applying compressed air to the upper pneumatic supply port).
Proceed as follows to fit the new diaphragm (443): • On valves with spiral-supported diaphragm, make sure to place
the support spiral (951) into the bonnet and verify that the last
• The contact surfaces of the diaphragm inside the body and the winding of the support spiral protrudes beyond the sealing lip.
bonnet must be clean and dry. The last winding of the support spiral must not end on a com-
• Turn the handwheel (961) in clockwise direction to take the pressor ridge.
upper valve section (165) to the closed position. • Remove any protection from the fastening grub screw of the
• On valves with spiral-supported diaphragm, make sure to place diaphragm.
the support spiral (951) into the bonnet and verify that the last • Screw in the diaphragm as far as it will go, i.e. until it rests
winding of the support spiral protrudes beyond the sealing lip. against the compressor (553), then back it off by a maximum of
The last winding of the support spiral must not end on a com- 180° to ensure it is correctly aligned.
pressor ridge. • Once the diaphragm rests against the compressor, never screw
• Remove any protection from the fastening grub screw of the it in further to avoid overloading of the diaphragm.
diaphragm. • The upper valve section must be taken to the open position
• Screw in the diaphragm as far as it will go, i.e. until it rests before the bonnet (165) is removed (see Section 8.3.2, Para. 1).
against the compressor (553), then back it off by a maximum of • On SISTO-16/20 valves, make sure that the centring boss of
180° to ensure it is correctly aligned. the diaphragm aligns with the „pocket“ in the valve body.
• Once the diaphragm rests against the compressor, never screw • Now place the bonnet (165) onto the body (100) and tighten the
it in further to avoid overloading of the diaphragm. bonnet (165) fastening bolts by hand.
• Turn the handwheel (961) in counter-clockwise, i.e. opening, • Run the actuator (SF/OF/AZ) to the closed position and tighten
direction until the diaphragm rests against the bonnet. Do not the bonnet bolts evenly and crosswise in accordance with the
turn any further. tightening torques table.
• On SISTO-16/20 valves, make sure that the centring boss of • Run the actuator (SF/OF/AZ) to the open position and verify the
the diaphragm aligns with the „pocket“ in the valve body. tightening torques of the bonnet bolts if necessary.
• Now place the bonnet (165) onto the body (100) and tighten
the bonnet (165) fastening bolts by hand. The required torques are given in section 10.
• Tighten the bonnet bolts evenly and crosswise in accordance
with the tightening torques table. - Installation of multi-part PTFE and TFM diaphragms see Section
8.3.1.1 .
The required torques are given in section 10.
- Diaphragms marked “MD 30” and “MD 40” with an “N” added
Diaphragms marked “MD 30” and “MD 40” with an “N” added after after the indication of the elastomer quality and featuring a faste-
the indication of the elastomer quality and featuring a fastening ning button on the back of the diaphragm are buttoned into the
button on the back of the diaphragm are buttoned into the compressor (553) by means of this button. Simultaneous pulling
compressor (553) by means of this button. Simultaneous pulling and turning on one side will easily remove the diaphragm (443)
and turning on one side will easily remove the diaphragm (443) from the compressor.
from the compressor.
When fitting the diaphragm on the body make sure that the sealing
When fitting the diaphragm on the body make sure that the sealing protrusion of the diaphragm is positioned normal to the flow direction.
protrusion of the diaphragm is positioned normal to the flow direction.
Replacing the actuator diaphragm of diaphragm actuators (see
8.3.1.1 Mounting of multipart PTFE- and TFM-diaphragms section 5.2.2)
with support ring (see section 8.3.1)
Spring to close (SF) and spring to open (OF) designs
The metallic support ring used for multipart PTFE- and TFM-dia-
phragms with rubber-made backing diaphragm has to be placed CAUTION These actuators feature pre-loaded springs.
with the grooved site to the backside of the PTFE/TFM diaphragm.
Mounted in this way, the smaller ring face will be oriented towards SF+OF Vent actuator and separate from the air supply system.
the bonnet. Undo four opposite hexagon nuts (920.3) and replace the
four hexagon head bolts (901.1) by suitable tie bolts. Tighten
the four hexagon nuts (920.3) on the tie bolts as far as they
will go. Unscrew the remaining hexagon nuts (920.3) around
the actuator case from the bolts (901.1).
SF Unscrew hexagon nuts (920.4/920.7) from the sliding stem
(202).
OF Unscrew the sliding stem (202) secured with Loctite from the
stem (200) using the locked hexagon nut (920.4).
15
SF+OF Evenly undo the four hexagon nuts (920.3) on the tie bolt CAUTION If during the functional check in the line with a
until the spring (950) tension is relieved. Remove the upper valve under pressure the hexagon nut (920.9) is found to rest on the
actuator case (151.2). bonnet assembly (172), the valve probably leaks in the passage. To
SF Unscrew the coupling (840) secured with Loctite together remedy the fault, take the actuator to the open position, undo the he-
with the sliding stem (202) from the stem (200). xagon nut (920.9) and unscrew the stem (200) from the coupling (840)
SF+OF Withdraw the upper diaphragm plate (550.3). Replace the by approx. one half-turn. Then lock hexagon nut (920.9) on coupling
defective actuator diaphragm (443.1). Effect reassembly in (840) again.
reverse order. Connect actuator to air supply system.
Double-acting design: air to close, air to open (AZ) handwheel or pneumatic actuator for sterile processes
- Vent actuator and separate from air supply system.
Replacing the diaphragm of SISTO-C
- Unscrew all hexagon nuts (920.3) from the upper actuator case
(151.2). On diaphragm valves, the diaphragm is the highest stressed com-
- Unscrew the sliding stem (202) from the stem (200) using loc- ponent. The diaphragm is not only subject to mechanical stress but
ked hexagon nut (920.4/920.7). also to wear caused by the medium. We recommend to regularly
- Withdraw the upper diaphragm plate (550.3). check the diaphragm at intervals to be individually stipulated depen-
- Replace the defective actuator diaphragm (443.1). ding on service conditions and actuation frequency. For checking
- Effect reassembly in reverse order. the diaphragm, remove the bonnet from the body.
- Connect actuator to air supply system.
Note: - Take valve to the open position.

When tightening the coupling (840) / sliding stem (202) on the stem
- Undo hexagon head bolts (901) to dismantle the bonnet (165).
(200), make sure to secure the connection with Loctite „medium“
again and take care that the bolt holes of the diaphragm and the - Take valve to the closed position. To do so, turn handwheel
bolt holes of the actuator case (151.1) register. Ensure that the (961) clockwise on manually actuated valves; supply com-
actuator diaphragm does not pucker. The stem (200) is secured pressed air to the upper control air supply port on actuators with
against rotation by a flat end in the compressor (553). air to open/air to close function and spring to open function;
release the air from the actuator in case of actuators with spring
CAUTION The hexagon nuts (920.4/920.7) act as a travel to close function.
stop in closing direction. They should be set so as to ensure that the
valve closes tightly at the relevant operating pressure. If during the - Turn counter-clockwise to dismantle diaphragm (443) with fa-
functional check in the line with a valve under pressure the hexagon stening thread. Diaphragms marked „MD 30“ and „MD 40“ with
nut (920.4) / hexagon nut (920.7) is found to rest on the upper actuator an „N“ added after the indication of the elastomer quality and
case (151.2), take the actuator to the open position and unscrew the featuring a fastening button on the back of the diaphragm are
hexagon nuts (920.4/920.7) from the sliding stem (202) by approx. buttoned into the compressor by means of this button. Simul-
one half-turn. Then lock the hexagon nuts again, tightly gripping the taneous pulling and turning on one side will easily remove the
lower hexagon nut (920.7). diaphragm (443) from the compressor.
pneumatic piston actuator for industry and building Proceed as follows to fit the new diaphragm (443):
services: Type LAP (see section 5.2.3)
• The contact surfaces of the diaphragm inside the body and the
The description for the replacement of the diaphragm can be found bonnet must be clean and dry.
in chapter 8.3.2. Before replacing the diaphragm please read chap- • Take the upper valve section (165) to the closed position as de-
ter 8.3.2 carefully and act accordingly. scribed above. (Close manually actuated upper valve sections
by turning the handwheel (961) in clockwise direction).
Dismantling of a pneumatic actuator from a valve/ reassem- • On valves with spiral-supported diaphragm, make sure to place
bling of the pneumatic actuator on a valve the support spiral (951) into the bonnet and verify that the last
winding of the support spiral protrudes beyond the sealing lip.
Dismantling The last winding of the support spiral must not end on a com-
- Vent actuator and separate from air supply system. pressor ridge.
- Loosen hexagon nut (920.9) (approx. one turn). • Remove any protection from the fastening grub screw of the
- Unscrew hexagon nuts (4 pcs.) (920.11). diaphragm.
- Turn coupling (840) clockwise, using a suitable tool, until the • Screw in the diaphragm as far as it will go, i.e. until it rests
piston rod (209/209.1/209.2) is completely screwed out. against the compressor (553), then back it off by a maximum of
- Lift actuator off bonnet assembly(172). 180° to ensure it is correctly aligned.
• Once the diaphragm rests against the compressor, never screw
Safety instructions it in further to avoid overloading of the diaphragm.
• The upper valve section must be taken to the open position be-
- Further dismantling of spring-loaded actuators may fore the bonnet (165) is removed (by applying compressed air to
only be carried out at the delivering factory. the lower pneumatic supply port of double-acting actuators and
- Actuators of the spring to open / spring to close spring-to-close actuators, or releasing the pressure of spring-to-
type are fitted with a spring mechanism. The studs open actuators).
(902.1) serving as tie bolts must never be cut or • On handwheel-actuated valves, turn the handwheel (961) in
undone. counter-clockwise, i.e. opening, direction until the heat barrier of
Reassembly of the pneumatic actuator the diaphragm rests against the bonnet. Do not turn any further.
• Always make sure that the arrow on the protruding identification
Installation of pneumatic actuator type LAP tongue of the diaphragm (443) points in the flow direction of the
valve seat. This requirement must be met for the valve to pro-
- Align actuator with bolt circle of bonnet assembly (172) using vide reliable shut-off. The diaphragm must not be fitted with the
stud (902.1) and place actuator on the bonnet assembly (172) arrow pointing at right angles to the flow direction, i.e. parallel to
(caution: mind the position of the air supply port). the weir inside the body (100).
- Tighten hexagon nut (920.10) crosswise. • Now place the bonnet (165) onto the body (100) and tighten the
- Screw coupling (840) onto piston rod (209/209.1) (3 to 4 th- bonnet (165) fastening bolts by hand.
reads). If required, cautiously move piston rod (209) (OF/AZ) in
the closed direction using compressed air.
- Take actuator to the open position using compressed air. Screw
coupling (840) onto piston rod (209/209.1) as far as it will go;
then back off one full turn.
- Lock hexagon nut (920.9) on coupling (840).
- Connect actuator to air supply system.
16
• On the upper valve sections (165) of handwheel-actuated 8.4 Replacing the valve disc
valves, tighten the bonnet bolts evenly and crosswise in accor-
dance with the tightening torques table. Undo hexagon head bolts (901) to dismantle the cover. The valve
• On valves fitted with actuators (SF/OF/AZ), run the actuator disc (746) is now lying loosely in the body, ready to be replaced.
to the closed position and tighten the bonnet bolts evenly and When replacing the disc, thoroughly clean all sealing surfaces be-
crosswise in accordance with the tightening torques table. fore fitting the new disc. Effect installation of the replacement valve
• On valves fitted with actuators (SF/OF/AZ), run the actuator to disc in reverse order, making sure to centre the valve disc (746) in
the open position and verify the tightening torques of the bon- the cover (160). Evenly tighten the hexagon head bolts (901).
net bolts if necessary.
8.5 Replacing the ball
The required torques are given in section 10.
Undo hexagon head bolts (901) to dismantle the upper body (101)
- Mounting of multipart PTFE- and TFM-diaphragms see section from the lower body (102). The ball (489) is now lying loosely in
8.3.1.1. the lower body (102) ready to be replaced. When replacing the
ball, thoroughly clean all sealing surfaces before fitting the new
- Make sure to evenly tighten the hexagon head bolts (901) ball. Evenly tighten hexagon head bolts (901) crosswise when
crosswise when fastening the bonnet (bonnet) on the body reassembling the upper body (101).
(100).
8.6 Valve reassembly
Replacing the diaphragm of SISTO-B
Valve reassembly shall be effected in reverse order to dismantling.
On diaphragm valves, the diaphragm is the highest stressed com-
ponent. The diaphragm is not only subject to mechanical stress but To maintain functional reliability, new gaskets shall be used when-
also to wear caused by the medium. We recommend to regularly ever the valve is reassembled.
check the diaphragm at intervals to be individually stipulated de-
pending on service conditions and actuation frequency. For chec- After reassembly and prior to commissioning / start-up, the valves
king the diaphragm, remove the bonnet from the body. shall be subjected to a leak test in accordance with DIN 3230, Part
3.
- Take valve to the open position. After reassembly and prior to commissioning/start-up, the valves
must be subjected to a leak test to DIN EN 12266. Observe sec-
- Undo hexagon head bolts (901) to dismantle bonnet (165). tion 6.3.1.
Proceed as follows to fit the new diaphragm (443):

9. Trouble-shooting
• The contact surfaces of the diaphragm inside the body and the
bonnet must be clean and dry: 9.1 General
• Take the upper valve section (165) to the closed position as described
above. (Close manually actuated upper valve sections by turning the SISTO valves and pneumatic actuators are robust in design. Nev-
handwheel (961) in clockwise direction). ertheless, malfunctions e.g. caused by maloperation, lack of main-
• On valves with spiral-supported diaphragm, make sure to place the tenance or improper use cannot be ruled out completely.
support spiral (951) into the bonnet and verify that the last winding of All repair and maintenance work shall be performed by skilled,
the support spiral protrudes beyond the sealing lip. The last winding competent personnel using suitable tools and original spare parts.
of the support spiral must not end on a compressor ridge.
We recommend to have this work performed by our service per-
• Remove any protection from the fastening grub screw of the sonnel.
diaphragm. The safety instructions in sections 2 and 8 must be complied with.
• Screw in the diaphragm as far as it will go, i.e. until it rests against
the compressor (553), then back it off by a maximum of 180° to 9.2 Faults > Remedial action
ensure it is correctly aligned.
• Once the diaphragm rests against the compressor, never screw 9.2.1 Leakage at the mating flanges
it in further to avoid overloading of the diaphragm.
• The upper valve section must be taken to the open position be- Possible causes:
fore the bonnet (165) is removed (by applying compressed air to
the lower pneumatic supply port of double-acting actuators and - contaminations/solids in the fluid
spring-to-close actuators, or releasing the pressure of spring-to- - erosion, corrosion, abrasion
open actuators). - excessive loads from pipeline forces or thermal stresses
• On handwheel-actuated valves, turn the handwheel (961) in
counter-clockwise, i.e. opening, direction until the diaphragm Remadial action:
rests against the bonnet. Do not turn any further. > Dismantle, clean and replace seal elements.
• Now place the bonnet (165) onto the body (100) and tighten the
bonnet (165) fastening bolts by hand. 9.2.2 Leakage at the cover/bonnet bolting or the bolting
• On the upper valve sections (165) of handwheel-actuated valves, of the mating flanges
tighten the bonnet bolts evenly and crosswise in accordance with
Possible causes:
the tightening torques table.
- compressive-stress relaxation
• On valves fitted with actuators (SF/OF/AZ), run the actuator
- seal element has settled as a result of high temperature fluc-
to the closed position and tighten the bonnet bolts evenly and
tuations
crosswise in accordance with the tightening torques table.
- impermissible pressure loads
• On valves fitted with actuators (SF/OF/AZ), run the actuator to
- poor maintenance
the open position and verify the tightening torques of the bonnet
- poor seal element resistance to temperature and fluid handled
bolts if necessary.
The required torques are given in section 10. Remedial action

> Re-tighten the bonnet/cover bolting (901).
- Mounting of multipart PTFE- and TFM-diaphragms see section > Replace the seal element (411) (diaphragm / joint ring)
8.3.1.1. after having removed the bonnet/cover bolting (902.1/920.1).
Clean the sealing surfaces carefully before inserting a new joint
ring.
17
9.2.3 Leakage caused by a diaphragm rupture 9.2.4 Seat leakage
Possible cause Possible cause

- Diaphragm rupture
- Foreign matter at the weir
Remedial action - Foreign matter in/on the diaphragm lip or damage
> Replace the defective diaphragm, see section 8.3. - Stop nut for closed position incorrectly adjusted
Remedial action
- Remove foreign matter from the weir and replace diaphragm if

necessary.
- Remove foreign matter in/at the diaphragm lip and replace
diaphragm if necessary.
- Re-adjust stop nut or replace diaphragm if necessary.
If you have any questions please contact the manufacturer.
10. Tightening torques (Nm) of bonnet / cover bolting

(Tightening torques only apply to the valve‘s temperature range between +5 and +40ºC)
SISTO-KB/KBS
Lining Diaphragm Nominal diameter (DN)

1)
Coating
015 020 025 032 040 050 065 080 100 125 150 200
Without coating EPDM, NBR,
Hard lining CSM, IIR 6 6 12 12 12 30 35 45 45 50 60 70
Coated
Soft lining EPDM, NBR, 5 5 10 10 10 25 30 40 35 40 45 50

CSM, IIR

SISTO-10/10S/10M
Lining Diaphragm Nominal diameter (DN)

1)
Coating
015 020 025 032 040 050 065 080 100 125 150 200 250 300
Without coating EPDM, NBR,
Hard lining CSM, IIR 6 6 8 15 15 25 35 50 35 45 65 75 75 75
Coated
Without coating
Hard lining PTFE 8 8 10 18 18 30 40 55 40 50 70 85 85 85
Coated (2 layer)
Soft lining EPDM, NBR 6 6 8 13 13 22 35 45 35 40 50 60 60 60

CSM, IIR
Soft lining PTFE 6 6 8 15 15 25 35 50 35 40 55 65 65 65

(2 layer)
KRV
Lining 1) Nominal diameter (DN)

020 025 032 040 050 065 080 100 125 150 200

Hard lining 20 20 20 35 40 50 60 80 85 90 90
Without lining 20 20 20 35 40 50 60 80 85 90 90

1) Hard lining = NR-H; PFA; PTFE; TFM
Coating = ECTFE; Rilsan
Soft lining = IIR; CSM
18
SISTO-16 / SISTO-16HWA/DLU/TWA
Nominal diameter (DN) 15 15 20 25 25 32 40 50 65 80 100 125 150 200

Diaphragm-Ø 40 65 65 65 65 92 92 115 168 168 202 202 280 280
Lining
1) 4hole 2hole 4hole 2hole 4hole 4hole
Coating Diaphragm
Without coating EPDM, NBR, 3 10 4 10 4 10 10 15 20 20 40 40 50 50
Coated CSM, IIR
Without coating PTFE, TFM 4 20 15 20 15 25 25 40 55 55 80 80 100 100

Coated (2 layer)
Hard lining EPDM, NBR, 10 6 10 6 12 12 18 24 24 48 48 60 60
CSM, IIR
Hard lining PTFE, TFM 18 13 18 13 22 22 36 50 50 70 70 90 90
(2 layer)
Soft lining EPDM, NBR, 8 5 8 5 10 10 15 20 20 40 40 50 50

CSM, IIR
Soft lining PTFE, TFM 10 6 10 6 12 12 18 24 24 48 48 60 60

(2 layer)
SISTO-16S
Nominal diameter (DN) 15 15 20 20 25 25 32 40 50 65 80 100 125 150 200
Diaphragm-Ø 40 65 65 65 65 65 65 92 115 168 168 202 202 280 280
Lining 4hole 2hole 2hole 4hole 2hole 4hole 2hole

1)
Coating Diaphragm

Coated CSM, IIR
Coated (2 layer)
Hard lining EPDM, NBR, 10 10 6 10 6 10 12 18 18 24 48 48 60 60
CSM, IIR
Hard lining PTFE, TFM 18 18 13 18 13 18 22 36 36 50 70 70 90 90
(2 layer)
Soft lining EPDM, NBR, 10 10 5 10 5 10 10 15 15 20 40 40 50 50
CSM, IIR
Soft lining PTFE, TFM 10 10 6 10 6 10 12 18 18 24 48 48 60 60

(2 layer)
PFA/PTFE/ EPDM, NBR, 3 6 6 10 12 18 18 24 48 48 60 60
TFM CSM, IIR
PFA/PTFE/ PTFE, TFM 4 13 13 18 22 36 36 50 70 70 90 90

TFM (2 layer)
SISTO-20
Nominal diameter (DN) 15 15 15 20 25 32 40 50 65 80 100 125 150 200
Diaphragm-Ø 40 65 65 65 65 92 92 115 168 168 202 202 280 280

Lining 1) 4hole 2hole 4hole 4hole 4hole
Coating Diaphragm

Coated CSM, IIR

Coated (2 layer)
Hard lining EPDM, NBR, 10 6 6 6 12 12 18 24 24 48 48 60 60
CSM, IIR
Hard lining PTFE, TFM 18 13 13 13 22 22 36 50 50 70 70 90 90

(2 layer)
Soft lining EPDM, NBR, 8 5 5 5 10 10 15 20 20 40 40 50 50

CSM, IIR
Soft lining PTFE, TFM 10 6 6 6 12 12 18 24 24 48 48 60 60

(2 layer)
PFA/PTFE/ EPDM, NBR, 3 6 6 6 12 12 18 24 24 48 48 60 60

TFM CSM, IIR
PFA/PTFE/ PTFE, TFM 4 13 13 13 22 22 36 50 50 70 70 90 90

TFM (2 layer)

19
SISTO-16RGA

Nominal diameter (DN) 15 20 25 32 40 50 65 80
Lining
Coating 1) Diaphragm-Ø 40 40 65 65 65 92 115 168
Without coating EPDM,NBR 3 3 4 4 4 10 15 20
SISTO-20M
Nominal diameter(DN) 10 15 20 25 32 40 50
Lining 1)
Coating Diaphragm-Ø 40 40 40 65 65 92 92
Without coating EPDM 3 3 3 4 4 10 10
SISTO-20TWC

Nominal diameter (DN) 15 20 25 32 40 50 65 80 100 125 150 200
Lining 1)
Coating Diaphragm-Ø 40 65 65 92 92 115 168 168 202 202 280 280
Without coating EPDM 3 4 4 10 10 15 20 20 40 40 50 50
SISTO-C
Diaphragm Diaphragm diameter (MD)

30 40 65 92 115 168 202 280

EPDM 1,5 3 8 12 14 18 32 40
TFM foil bonded 1,5 3,5 8 12 18
PTFE, TFM (2-layer) 2 4 10 18 30 40 60 75
SISTO-B
Diaphragm Diaphragm length (ML)

32 46 52 58 67 82 90 108 132 158 226 260 304

EPDM 0,8 3,5 2,5 6 8 12 15 25 30 45 30 35 50
TFM foil bonded 1 4 2,5 7 9 13 17 26

PTFE, TFM (2-layer) 2 6 8 10 15 18 28 35 50 35 40 55
SISTO-RSK
Lining 1) Nominal diameter (DN)
Coating 025 032 040 050 065 080 100 125 150 200 250 300

Without coating 8 20 20 15 15 20 20 30 30
Soft lining 8 15 15 10 10 10 10 15 15
lining
Hard 8
12 12 10 10
15 15 20 20

SISTO-RSKS
Nominal diameter (DN)
Lining
1)
Coating 025 032 040 050 065 080 100 125 150 200 250 300
Without coating 8 20 20 30 30 30 30 40 40 50
Soft lining 8 15 15 20 20 15 15 25 25 30
Hard lining 8 12 12 20 20 20 20 20 20 25
LAD SF/OF/AZ

Flanged actuator diaphragm Size
between
100 150 220
upper and lower part
of the actuator 10 12 15

20
11. Addition of the operating instructions which corresponds to the 94/9/EC Directive
(ATEX100)
Security
This symbol refers to safety precautions, which must be respected in reference to the use of valves in
potentially explosive atmospheres according to the 94/9/EC Directive (ATEX 100a) to avoid personal
injuries and damages to property.
♦ You have to mind that inadmissible operating methods are avoided if the valves are used in potentially explosive at-
mospheres. In particular, the overstepping of the limitated operating maximum temperature is unacceptable.
♦ The user is bound to only install and use explosion-proof working material in potentially explosive atmospheres.
Installation
♦ In principle valves have to be included in the equipotential setting of the system if they are used in potentially explosive
atmospheres.
♦ The pneumatic actuators chamber of the type series SISTOMAT-LAP and SISTOMAT-LAD has to be connected to an
not explosive air valve or an air tank for ventilating during the use in potentially explosive atmospheres.
Operation
♦ The system and thereby the interior of the valve, which comes into contact with the medium, should always be filled with
conveyed material during the valve‘s use, so that no explosive atmosphere can be created there. The user has to install
appropriate monitoring measures if he isn’t able to guarantee that, see ATEX 100a, appendix II, section 1.5.5 and EN
1127-1.
♦ The surface temperature of the valve‘s body corresponds to the temperature of the transported material. In each case
the system‘s user is responsible for the observance of the working temperature. The highest authorised temperature of
the material depends on the temperature class in each case.
♦ The heating of the valves components by the environnement or by sun radiation shall be avoided.
♦ Additional mechanical load on the products (for example external forces and torques) must be avoided.
Maintenance
♦ The user is responsible for maintenance works so that no ignition sources appear (for example electrostatic discharge,
mechanically created spark).
♦ The user should periodically verify the equipment tightness of the body and the different tightness ranges for example
with the help of a maintenance programm.
♦ In principle, dust and dirt should be avoided on all valve surfaces.
♦ You have to use a wet cotton cloth to avoid electrostatic discharge while you are cleaning plastic surfaces and plastic-
coated surfaces.
♦ The spare parts must be exclusively original SISTO parts.
Declaration
♦ Valves are components and they do not have their own potential source of ignition and are thus not covered by the
94/9/EC Directive and must not be indicated by the reference ATEX.
If the instructions laid down for “safety, installation, operation and maintenance/servicing” are not complied with,
proper operation of the valve within the meaning of Directive 94/9/EC (ATEX 100a) is not ensured. In this case, the
valves must not be used in potentially explosive atmospheres.
The use of faulty valves in potentially explosive atmospheres is not authorized in each case.
alterations are subjet to technical development
sales document, no technical document,
24.01.2014
0570.821/20-10 - ORIGINAL
SISTO Armaturen S.A.

Zone Industrielle • 6468 Echternach • (Luxembourg)
Tel. (+352) 32 50 85-1• Fax (+352) 32 89 56 • e-mail: sisto@ksb.com
Date 11.06.2018
DnD 150 DC13
Rev 00
Pump DnD 150
P a g e | 71
DnD-09
CHECKLIST PRE-
COMMISIONING
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I.O.M. 049-1806067-004 DND 150 DC13 PT RPP

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DEWATERING & DREDGING PUMP

DnD 150 DC13

I.O.M – INSTALLATION, OPERATION

WARRANTIES & COPYRIGHT

1. WARRANTIES replaced by KSB. No separate warranty shall apply

the date of delivery (or in the case of diesel- or replaced by KSB.

are found to be defective in materials or b) Failures or damage due to misapplication,

workmanship, or do not conform to any applicable abuse, improper installation or abnormal

drawings and specifications approved in writing by conditions of operation.

manufactured pumps) do not perform in intentional or otherwise, above or below rated

quotation (within the tolerances specified in by anyone other than an authorized

applicable Australian Standards), then KSB will, at representative of KSB.

parts or Goods provided that: of KSB

the Goods; any equipment or other goods of other

performance of pumps other than in a test equipment or other goods.

the Purchaser. tests will proceed in the absence of the Purchaser

3.2 Only such descriptions, specifications, drawings or its representatives.

without KSB’s prior written consent. required.

4. INSPECTION AND TESTING 5. INTELLECTUAL PROPERTY RIGHTS

inspections through KSB’s nominated Property Rights or patent applications. The

Original Equipment Manufacturer

This manual contains important information for reliable, proper and

These operating instructions contain fundamental information that must be complied

1.2.1. Safety Marking

Definition of safety symbols/markings.

Use to draw your attention to important information that will facilitate

Indicates a hazardous situation which, if not avoided, could result

Indicates a hazardous situation which, if not avoided, could result

Indicates electrical danger

Instruction attached directly to the machine, such as:

 Arrow indicating the direction of rotation

1.2.2. Personnel Qualification and Training

Personnel responsibilities, competence and supervision must be clearly defined by the

1.2.3. Non-Compliance with Safety Instructions

 Failure of important machine/unit functions

1.2.4. Safety Awareness

1.2.5. Safety Instructions for Operators

1.2.6. Safety Instructions for Maintenance, Inspection and Installation

1.2.7. Unauthorized Modification and Manufacture of Spare Part

1.2.8. Unauthorized Modes of Operations

1.2.9. Assembly and Disassembly Safety

 Before dismantling or reassembly, secure the pump so as to make

2. TRANSPORT & STORAGE

Pump set transport and storage instructions are intended as a guide

Proper lifting and safety practice must be observed at all times.

 If the pump/unit slips out of the suspension arrangement, it

Total dry weight for Pump Set up to ± 8500 kg!

Figure 2.1 Pump Set Lifting Method

Not recommended to Push or Pull pump set without Skid Runner,

Figure 2.2 Pump Set Position into The Sump

Protect all stored goods against humidity, dirt, vermin and

2.2.1. Pump Storage

 In freezing environments, water must be prevented from collecting

2.2.2. Driver Storage

 Covers or tarpaulins used to protect the equipment against the

2.2.3. Vacuum Pump Storage

2.2.4. Control Panel & Electrical Accessories Storage

 Control Panel & electrical accessories must be protected against

Figure 3.1 DnD 150 DC13