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Tsurumi Pump LB Series Manual

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OVERHAUL MANUAL
LB series
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Summary of Contents for Tsurumi Pump LB Series

  • Page 1 OVERHAUL MANUAL LB 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 LB-480-52 | LB-800-52 The following is a guideline for the overhaul of the 0.48kW and 0.75kW Tsurumi LB 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: LB-480-52)

  • Page 5: Table Of Contents

    Sections • Electrical Testing Page • Inspect Pump Discharge Page • Inspect Pump Casing Page • Inspect Oil Chamber Page • Inspect Mechanical Seal Page • Motor Inspection Page • Pump Re-Assembly Page...
  • Page 6 Tools Required...

  • Page 7: Electrical 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 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 (Disconnected) Outer Cover Disassembly Disconnect the three bullet connectors that connect the cable to the motor stator. Remove handle, and set the cable aside. Remove discharge flange from outer cover. A damaged discharge flange gasket, or deformation in the outer cover or discharge flange can cause water to leak at these points, reducing performance.
  • Page 14 Remove Outer Cover With the handle and cable removed, the outer cover should lift off of the pump. It may be necessary to lay the pump on its side, and carefully tap the outer cover with a rubber or plastic mallet to loosen it from the pump. Remove the head cover and inspect the packing and O-ring for damage or deformation.

  • Page 15: Inspect Pump Casing

    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 16 Remove Strainer Place the pump with strainer upside down, and remove the three hex screws securing the strainer stand. With the strainer stand removed, inspect the strainer, suction cover, pump casing and impeller for wear and damage. Any worn components should be replaced to regain original performance of the pump. Remove any foreign debris from the wet end.
  • Page 17 Remove Pump Casing Lift the rubber pump casing off of the oil casing. It may be necessary to carefully pry the pump casing away from the oil casing with a flat blade screwdriver. If there is excessive abrasive wear or the pump casing is damaged, it should be replaced.
  • Page 18 Stainless Steel Shaft Sleeve & V-Ring Remove Impeller Hex Cap Nut With a correct socket on a cordless impact Washers driver, remove the hex cap nut and washers securing the impeller. It may be necessary to hold the impeller in place with pliers while unfastening the hex cap nut.

  • 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 Drain and Inspect oil Oil Casing Oil Plug To drain the oil, remove the Oil Plug located on the oil casing, on the side of the pump. 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 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) bolts securing the oil casing. * Once these are separated, oil WILL leak out.
  • Page 23 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 Remove Oil Lifter The oil lifter is press-fit into the oil casing. Carefully lift this off to allow removal of the stationary portion of the mechanical seal.
  • Page 27 Remove Lower Stationary Seal Using a punch the same size as the seal, carefully tap it out of the casing onto a soft surface. The seal should not be re-used, but in case of inspection, don’t crack or damage it.
  • 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 / Inspect Capacitor Remove the (3) bolts securing the motor head cover from the motor frame. Remove the motor head cover and packing. Capacitor should be visible at this point. If capacitor visibly appears to be bulging, or is leaking electrolyte, it has over-heated and needs to be replaced.
  • 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 Motor Protector Capacitor Test Capacitor The LB-800-52 pump will contain a different style capacitor and a motor protector. Disconnect the leads of 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 34 Remove Motor Bracket Place the motor on its side and tap the end of the shaft with a RUBBER OR PLASTIC hammer. (A metal hammer can cause damage to the shaft end not allowing the impeller to be replaced.) Place the motor upright and remove the motor bracket, taking care while pushing the wires through the bracket. Motor Bracket...
  • Page 35 Inspect Rotor, Stator and Bearings With the motor bracket out of the way, pull up on the upper bearing and the rotor assembly should slide out. If the stator does not visibly have evidence of being burned, but is wet from oil or water, it will need to be cleaned with Stator compressed air/mineral spirits and baked in...
  • Page 36 Replace Bearings Spin bearings. If bearings appear to wobble or spin Bearing rough, they should be replaced. A bearing puller puller will be necessary to properly remove bearings. When re-installing NEW bearings, it is recommended to heat the bearings and the inner diameter expands.
  • Page 37 ( REF.: for LB-480 )
  • Page 38 Remove Upper Stationary Seals Using a punch the same size as the seal, carefully tap it out of the casing onto a soft surface. The seal will not be re-used, but in case of inspection, don’t crack or damage it.
  • Page 39 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 40: 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 41 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 42 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 43 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 previously.
  • Page 44 Secure Motor Assembly Re-install capacitor and attach leads from stator. For reference, for LB-480, 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 45 Secure Motor Assembly For the LB-800 pump, the wiring is different due to the motor protector. The red wire connects to the motor protector, white to white, and blue to the capacitor. The second blue wire is connected capacitor to capacitor.
  • Page 46 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 47 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 48 Reassemble Wet End Place V-ring and shaft sleeve assembly onto motor shaft with flat face of the shaft sleeve away from motor and rubber V-ring towards the motor. Then replace the wear ring and impeller. Impeller vanes should face away from the motor. Secure impeller with flat washer, lock washer and acorn nut.
  • Page 49 Reassemble Wet End Replace pump casing, suction cover, and strainer. Be sure water channels in pump casing align with the waterways in the oil casing. Secure with the (3) hex bolts.
  • Page 50 Reassemble Outer Cover Carefully place packing over motor head cover. Place O-Ring around motor frame and place outer cover over the motor assembly.
  • Page 51 Reassemble Top End Connect bullet connectors of cable assembly to leads from motor housing. REF.) LB-480/LB-800 : Yellow/Green – Yellow/Green, Blue – White, Brown – Red (for other models please refer to the operation manual) Bullet connectors will ‘snap’ when they are fastened properly. (The installation has to be performed by the qualified electrician only!) LB-480/LB-800 LB-800A...
  • Page 52 Reassemble Top End Assemble the handle with hex bolts, and the discharge hose coupling + gasket with acorn nuts. Place cable leads back into the outer cover. And fasten the cable gland firmly using (2) hex bolts. Fix cable to the handle with cable clip. Discharge Hose Coupling cable...
  • 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.
  • 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. To test the LB-480A or LB-800A pump, the circuit of the relay will need to be closed.
  • Page 56 OVERHAUL MANUAL LB series...

This manual is also suitable for:

Lb-480-52Lb-800-52

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