Tsurumi Pump LSC Series Overhaul Manual

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OVERHAUL MANUAL

LSC series

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Page 1 OVERHAUL MANUAL LSC series...
Page 2 Release from Liability Upon reading this, the user of the respective Tsurumi product and Overhaul Manual acknowledges and understands Tsurumi Europe shall not be held liable for any user injury that occurs during the inspection and disassembly/assembly of the product. The users also acknowledge that they will be held responsible for any damage or destruction inflicted onto the product, and/or for the loss of parts during inspection and self-performed maintenance.
Page 3 OVERHAUL MANUAL LSC1.4S-51 | LSCE1.4S-51 The following is a guideline for the overhaul of the 0.48kW Tsurumi LSC Series submersible pumps. Use this guide, along with the parts list, exploded view diagram, and operation manual for your particular pump model to disassemble, inspect, and rebuild your pump to factory conditions.
Page 4 Exploded View (Reference: LSC1.4S-51)
Page 5: Table Of Contents
Sections • Insulation Resistance Testing Page • Inspect Pump Discharge Page • Inspect Wet End for Wear Page • Inspect Oil Chamber Page • Inspect Mechanical Seal Page • Motor Inspection Page • Pump Re-Assembly Page...
Page 6 Tools Required...
Page 7: Insulation Resistance Testing
Electrical Testing Perform proper electrical testings. Please refer to the operation manual. All electrical work must be performed by an authorized electrician only in compliance with local electrical equipment standards and internal wiring codes. Never allow an unauthorized person to perform electrical work because it is not only against the law, but it can also be extremely dangerous.
Page 8 Cable Inspection Measure and inspect pump cable. If there are any cuts or other deformities in the cable, or the cable is less than the original length, the cable should be replaced. Inspect cable plug for damage and ensure that grounding prong is intact for safe operation.
Page 10: Inspect Pump Discharge
Inspect Pump Discharge If your pump motor is running but is not performing as new, there could be foreign debris stuck at the pump end or beneath the outer cover, or leaking from the discharge flange or packing (gaskets).
Page 11 Prepare for Disassembly With a paint pen or marker, make orientation marks on the strainer, oil casing, and outer cover to ensure proper orientation upon re-assembly.
Page 12 Motor Casing Visual Inspection Remove the handle. Then, remove the two bolts securing the cable gland to the outer cover. Carefully wiggle the cable assembly out of the motor casing and inspect the connections. If there is oil and/or water present in this area, the motor assembly will need to be disassembled for inspection and repair.
Page 13 Bullet Connectors Outer Cover Disassembly (Disconnected) Packing Disconnect the three bullet connectors that connect the cable to the motor stator. Set the cable aside. Remove the outer cover. A deformation in the outer cover can cause water to leak at these points, reducing performance.
Page 14: Inspect Wet End For Wear
Inspect Pump Casing for Wear and/or Debris If your pump motor is running but is not performing as new, there could be wear to the impeller and wear plate or foreign debris stuck in the strainer or pump casing.
Page 15 Pump Casing Stand Remove Lower Portions To begin removal of the bottom plate (strainer), remove the hex bolts and plain washers from the bottom plate; best performed with the pump stood upside-down. Strainer (Bottom Plate)
Page 16 Swing Check Valve Bottom Plate Once the bottom plate is removed, the swing check valve may be inspected and removed if necessary. If the swing check valve exhibits any excessive wear or damage, this could greatly affect the pump’s performance Bottom Plate and should be replaced.
Page 17 Remove Lower Portions Remove the hex bolts and their plain washers to remove the stand. Remove the suction cover by lifting it off from the pump casing. Suction Cover Pump Casing Remove the pump casing. It may be necessary to use a screwdriver to gently loosen the pump casing from its position.
Page 18 Remove Impeller Wear Ring Shaft Sleeve Remove the impeller by unscrewing the hex cap nut, w/ V-Ring the spring washer and plain washer. It may be necessary to hold the impeller with pliers. Lift the impeller off the rotor. Remove the shaft sleeve and V-ring by sliding them off the rotor.
Page 19: Inspect Oil Chamber
Inspect Oil Chamber It is recommended to inspect the oil every 6 months of operation. If there is water in the oil chamber or the oil level is low, this is evidence of a worn mechanical seal, which should be replaced before irreparable damage or bodily injury occurs.
Page 20 Oil Plug Drain and Inspect Oil To drain the oil, remove the oil plug and its packing, located on the side of the oil casing. Oil casing may be under pressure, so be sure to wear eye protection, and shield the oil from spraying everywhere.
Page 21: Inspect Mechanical Seal
Inspect/Remove Mechanical Seal If oil or debris was found in the oil chamber, or oil level is low, it is necessary to change the mechanical seal.
Page 22 Remove Oil Casing If there is evidence that the mechanical seal is leaking (water or debris in the oil or motor has failed the Megger test), it will be necessary to remove the oil casing from the motor frame. Using a hex bit, remove the (3) hex socket cap bolts securing the oil casing.
Page 23 Oil Lifter Inspect Oil Casing, O-Ring, Oil Lifter, and Mechanical Seal. It is recommended to use only new packings and O-rings upon re-assembly, so the O-ring will NOT be re-used. Check for debris, or grit in the oil chamber, and make sure oil lifter is not cracked or otherwise damaged.
Page 25 Oil Lifter Oil Lifter Remove Oil Lifter The oil lifter is press-fit into the oil casing. Stationary Carefully lift this off to allow removal of the stationary portion of the mechanical seal. Portion of Mechanical The stationary seal may be gently tapped out of Seal the oil casing using a tool with similar diameter.
Page 26 Mechanical Seal O-Ring Mechanical Seal With the oil casing removed, the mechanical seal will now be exposed. The O-ring will also be visible now. It may be removed and inspected for damage. Replace if necessary.
Page 28 Remove Lower Rotary Seal (Impeller Side) With two flat blade screwdrivers, CAREFULLY pry the upper portion of the rotary mechanical seal up and remove this face along with the spring. Take care not to damage the rotor shaft with the screwdrivers.
Page 29 Remove Upper Rotary Seal (Motor Side) With the lower seal and spring removed, then remove the upper seal. Take care not to damage the rotor shaft with the screwdrivers. The bottom of the mechanical seal may be identified by the rectangular indentation...
Page 30: Motor Inspection
Motor Inspection If your pump is tripping a circuit breaker or other device, this is evidence of an internal short in the motor or the cable. If your pump is making abnormal grinding noises or doesn’t spin, this is evidence of damaged bearings. Both would require disassembly and inspection of the motor components.
Page 31 Remove Head Cover Capacitor On top of the pump assembly, with the outer cover and packing removed, remove the hex bolts and their plain washers. The head cover may now be removed. * It is suggested to prop the pump assembly on some form of support to avoid resting the weight of it on the rotor.
Page 32 Test Capacitor Using wire cutters, cut the zip ties securing the wires going to the capacitor. Remove the lead wires from the capacitor. To avoid injury, discharge the capacitor by attaching the leads of your multi-meter to the leads of the capacitor while in Voltage AC setting.
Page 33 Wave Washer Rotor Remove Motor Bracket The packing and motor bracket may be removed by gently wiggling it until it loosens from the rotor bearing. (It may be necessary to place the motor on its side and tap the end of the shaft with a RUBBER OR PLASTIC hammer.
Page 34 Inspect Rotor, Stator and Bearings Stator Spin bearings. If bearings appear to wobble or spin rough, they should be replaced. A bearing puller and bearing heater will be necessary for proper disassembly/assembly If the stator does not visibly have evidence of being burned, but is Wave wet from oil or water, it will need to Washer...
Page 35 ( REF.: for LSC1.4S )
Page 36 Remove Upper Stationary Seals Using a punch the same size as the seal, carefully tap it out of the casing onto a soft surface, or use a flat-head screwdriver to carefully lift the seal out. The seal will not be re-used, but in case of inspection, don’t crack or damage it.
Page 37 Inspect All Components for Replacement With disassembly complete, inspect all the components for wear or damage, and make a list of components that will need to be replaced. All Packings and O-rings should be replaced along with the mechanical seal and oil. For all other parts, use your discretion.
Page 38: Pump Reassembly
Pump Reassembly Once all components have been verified to be in operable condition, we can now re-assemble the pump. New O-Rings and Packing materials are available as a kit, and should always be used upon re-assembly...
Page 39 Layout Mechanical Seal for Proper Placement It is very important that the mechanical seal components are oriented properly when installed. This is how they should appear on the shaft. Left to right = Top to bottom. Rectangular Indentation Mechanical Seal (Upper/Motor Side) (Lower/Impeller Side)
Page 40 Reassemble Stationary Seals Coat mechanical seal components with fresh oil. Carefully press upper stationary mechanical seal (ceramic) into motor frame, and press lower stationary seal (SiC) into the oil casing. Ensure seals are properly seated and sitting parallel to the casings. Press oil lifter into oil casing...
Page 41 Reassemble Motor Place rotor assembly back into motor frame/stator assembly. Place wave washer back onto top of upper bearing, and place motor bracket. Be sure to re-align the motor bracket and packing per the alignment marks drawn during disassembly.
Page 42 Reassemble Motor Be sure to re-align the motor bracket and packing per the alignment marks drawn during disassembly.
Page 43 Secure Motor Assembly Re-install capacitor and attach leads from stator. For reference, the blue wire goes on the left (single lead), and black is on the top right, and red wire is bottom right. Replace head cover gasket and install head cover with the three securing bolts. Be sure the white, red and green/yellow wires feed through the top of the head cover.
Page 44 Reassemble Rotary Seals Coat rotor shaft with oil and carefully press upper rotary seal (motor side) onto shaft until it touches the upper stationary seal. Place spring against rotary seal, and press lower rotary seal (chamfered edge – impeller side) on the shaft. * Placing the pump upside down on a support (to protect the wires and capacitor) The upper/motor side of the mechanical seal can be identified by the shown rectangular indentation...
Page 45 Reassemble Oil Casing Rotary seals will quickly compress on shaft, so run them back and forth on the shaft until oil casing is ready to be bolted to motor frame. Replace O-Ring and tighten bolts, fastening oil casing to motor frame, and turn pump on its side. Spin motor shaft to ensure there is no binding and shaft spins smoothly.
Page 46 Reassemble Wet End Insert the wear ring, shaft sleeve and V-ring, and then the impeller. (flat face of the shaft sleeve away from motor and rubber V-ring towards the motor) Secure the impeller with the plain washer, spring washer, and hex cap nut.
Page 47 Reassemble Wet End Suction Cover Insert the pump casing, and then position the suction cover on top. Pump Casing...
Page 48 Reassemble Wet End Position the stand on the pump assembly, and then secure it with the (3) hex bolts with their plain washers.
Page 49 Reassemble Bottom Plate Secure the swing check valve to the bottom plate with the rubber washer (packing), plain washer, and hex nut. Position the bottom plate on the pump assembly, and secure in place with the (3) hex bolts and their plain washers. Swing Check Valve...
Page 50 Reassemble Outer Cover Place the packing on the motor head cover. Place the outer cover over the pump assembly, and make sure to pull the wires through its opening. Connect the wires protruding from the gland of the outer cover to those of the cable via bullet connectors. LSC1.4S : Yellow/Green –...
Page 51 Reassemble Top End Gently push the wires and the bullet connectors into the opening of outer cover, and slide the metal gland over the rubber end of the cable. Secure in place with the bolts.
Page 52 Handle Reattach the Handle Cable Clip Assemble the handle with hex bolts, and the discharge hose coupling + gasket with acorn nuts. Fix cable to the handle with cable clip. Cable clip attached to the handle is necessary in order to relieve stress from the cable and wire connections (under the gland) when in tension.
Page 53 Air Tightness Test Oil Casing With an air tight fitting, test if the mechanical seal is seated properly. If the chamber can hold for more than 1 minute, the seal is seated properly and will not leak.
Page 54 Fill With New Oil Provide the pump with new oil by placing it on its side, remove the oil plug, and carefully pour in the correct amount of oil. Close the oil plug. Oil Plug...
Page 55 Perform Run Test Connect pump cable to single phase power with correct voltage. Make sure pump is pushing air and there is no abnormal noises coming from the unit. Pump should make a steady humming sound when running. It may be necessary to place the pump on its side and use a thin rod or screwdriver to push in the swing check valve, in order to ensure the pump is pushing air for the test.
Page 56 OVERHAUL MANUAL LSC series...

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Lsc1.4s-51 Lsce1.4s-51