Sundyne Gearbox Upgrade

• Costly Process Downtime
• Liability Exposure
• Health and Safety Issues
• Part Replacement Costs
• Repair Costs
• Environmental Impact
• Intensified Vibration Levels
• Increased Noise
• Higher Energy Consumption
• Increased NPSH Requirements
• Rework and Recycle Needs
• Fit and Assembly Problems

We work diligently to ensure appropriate legal action is taken when replicators are in violation of patents or misrepresent the parts they’re providing customers

The new Sundyne Reliability Assurance Kit brings the reliability and efficiency of our recently released upgraded component parts to older generation machines. The upgraded components in the kits are designed to increase reliability and make units more tolerant to condition changes. These kits offer a simple and cost-effective way to rebuild a unit from the process seals all the way through the gearbox, improving performance and simplifying inventory management without the need for a direct replacement or a full conversion.

Key Benefits of Reliability Assurance Kits:

• Improved reliability & MTBF – genuine and specific spare parts for each unit.
• Better inventory management – the Sundyne Genuine Parts in the RAK are under a single part number versus having to track dozens of numbers in an ERP system.
• Ease of maintenance – parts are contained in a single heavy-duty package, which is easily purchased, stored and accessed by maintenance teams.
• RAKs are sealed to reduce – and even eliminate – part contamination and corrosion.
• Easy replenishment – used parts can be restocked by ordering a kit refill.

Parts and Data Included in the Reliability Assurance Kits:

• Upgraded Anti-Friction Bearings – increased efficiency and shaft longevity.
• Lube Pump Anti-Rotation Plate – higher radial shaft load tolerances.
• Gearbox SundSEAL – minimizes leakage, increases life span, and reverse pressure capable.
• Desiccant Breather – prevents moisture, reduces internal rust, and maximizes efficiency.
• Other standard wear parts – process seals, nuts, bolts, washers, screws, o-rings, etc.
• Spec Sheets.
• Performance Curves.
• Instruction and Operation Manuals, including cross-section drawings.

The Sundyne Gearbox Exchange Program offers end users a chance to return their Sundyne LMV, LMC, BMP or BMC gearbox to original factory performance specifications. The exchange is quick and cost effective while providing the many benefits of a brand new Sundyne gearbox. Once a customer puts in a request, Sundyne will ship the gearbox while the old unit is returned for a rebate.

Key Benefits of Gearbox Exchange:

• New unit provided with partial rebate credit for returned old unit.
• Significant savings compared to a new gearbox purchase.
• Includes most recent technology, parts, and metallurgies (seals, filters, lubrication, etc.).
• Improved reliability and extended operating life.
• Reduced noise and vibration levels.
• Easy and quick change in maintenance workshop (plug-in concept).
• Improved parts inventory, lowered risk.

Gearboxes received through the Exchange Program include a 18-month warranty from start-up, or 24 months from shipment. Note that normal delivery lead-time is 2 weeks for standard gearboxes with standard paint.

The new Gearbox Output SundSEAL is a proprietary, easy-to-upgrade seal that delivers a robust sealing interface. The new seal is proven to reduce leakage which, when configured with proper lubrication and system pressure management, vastly improves overall operational efficiency.

The Gearbox Output SundSEAL is suitable for any customer, application, or operating condition with an existing LMV/BMP-3XX pump or LMC/BMC-3XX compressor in operation.

The straightforward retrofit capability, makes the SundSEAL is an easy upgrade for existing Sundyne integrally geared pumps.

Reduction in Total Cost of Ownership

• Reduced downtime, improved operation time
• Extended maintenance intervals and reduced maintenance costs – longer seal life

Optimized Performance

• New port design for optimal drainage and pressure management
• Minimum leakage reduction of 50%
• The lower gearbox housing now has three additional passage ways connecting the oil sump area to the SundSEAL, improving the seal’s ability to control oil leakage

Added Gearbox Protection

• Reverse Pressure Capability up to 275 psi creates a barrier between the process seals and the gearbox interior, keeping process fluid out of the gearbox

Quick retrofit capability

• Easy, field installed upgrade for existing units

Sundyne Genuine Part

• Superior factory developed solution

All Sundyne integrally gear drive pumps should be upgraded to the new anti-friction bearing (excluding LMV-34X models)

Journal bearings should be replaced during any gearbox maintenance or reliability upgrade

Applies to all Sundyne integrally geared drive pumps – LMV/BMP-3XX models

The Sundyne desiccant breather is designed to protect your gearbox from corrosion and contamination

Key Benefits of the Sundyne Lube Oil Pumps:

• Reduction in total cost of ownership – designed to keep Sundyne machines operating longer at lower temperatures, minimizing downtime, extending maintenance intervals and reducing maintenance costs.
• Sundyne Genuine Part – superior factory developed solution with a new rugged design that eliminates pin shear.
• Added gearbox protection – improved gearbox lubrication.
• Optimized performance – with the addition of the carbon bushing and the newly developed drive lugs help reduce wear inside the lube pump.

Key Technical Specifications of the Sundyne Lube Oil Pump:

• Wear between the drive pins and the gearbox input shaft was improved. After an analysis of the contact area between the old drive pins and the input shaft, drive lugs were developed to reduce wear between the two parts.
• Wear inside the lube pump is also reduced by the addition of a carbon bushing and a coated bronze bearing, as shown by the red arrows in the photo below.
• New lube pump PU01AB06 height reduced by 0.045” from PU01AB05 – providing additional clearance for older models.

Key Benefits of Sundyne Bearing & Lube Anti-Rotation Plate:

• Increased operational reliability and robustness
• Designed for use with all existing Sundyne lube pumps
• Field installation capability with retrofit option for all LMX-31X models in operation.
• Superior lube pump anti-rotation reliability – through elimination of spiral pin.

Key Technical Specifications of Bearing & Lube Anti-Rotation Plate:

• The new bearing plate has a larger diameter lube pump housing bore and four threaded holes that locate and anchor the anti-rotation plate.
• To use the PL01AA99 anti-rotation plate, existing bearing plates require replacement and upgrade to PL11AA02XXXXXX00.
• The PL11AA02XXXXXX00 bearing plate was configured so that all previous bearing plate versions could be obsoleted. Bearing plate part numbers that have been obsoleted include – PL01AA05XX, PL01AA17XXXX, PL01AA96XX0000
• The redesign requires two additional parts be sold with the bearing plate. To simplify, four common bearing plate builds (representing 90% of all 31X sales) have been configured that include the additional parts – consult Sundyne for configurations.

This upgrade is available to you:

Sundyne pumps and compressors are designed to last. One of the original Sundyne pumps with a serial number from the 1960’s is still in operation today. In order to maximize the life of a Sundyne gearbox, routine maintenance and repairs must be completed. Repeated assembly and disassembly of the gearbox housing causes wear of the close tolerance alignment bolt holes. The upgraded Sundyne alignment bolts use new material that eliminate wear and prevents misalignment of the gearbox housing.

Key Benefits of Sundyne Gearbox Alignment Pins:

• Reduction in total cost of ownership – eliminates misalignment of gearbox housings.
• Added gearbox protection – eliminates unnecessary vibration from misalignment.
• Sundyne Genuine Part – superior factory developed solution.
• Quick retrofit capability – easy, field installed upgrade for existing units.

Key Technical Specifications of Sundyne Gearbox Alignment Pins:

• Smaller thread diameter and a gentle lead in chamfer to the bolt shank – eliminates wear on the gearbox housing alignment hole.
• Interchangeable with existing housings – the hold size has not changed.
• Same threads as older bolts – same nuts and washers can be used.

Proper lubrication is critical to keeping Sundyne pumps and compressors operating at optimum levels. In order to ensure the lubrication system is functioning properly, accurate oil levels must be maintained. The new Sundyne low foam sight glass provides a significant improvement from previous designs, providing much more accurate oil level readings at all oil temperatures and operating speeds.

Key Benefits of Sundyne Low Foam Sight Glass:

• Added gearbox protection – accurate oil level readings allow customers to be proactive in maintaining their Sundyne machine, eliminating unnecessary failures.
• Easier maintenance – quickly identify oil levels and have confidence the readings are accurate.
• Quick retrofit capability – easy, field installed upgrade for existing units.
• Sundyne Genuine Part – superior factory developed solution.

Key Technical Specifications of Low Foam Sight Glass:

• The low foam sight glass works on the principle that the oil is maintained in the extended sight glass for a longer period allowing entrained air to be released.
• Extensive factory testing, which included running a gearbox at 34,000 rpm for an extended period and filling the gearbox with cold oil (at its pour point) to ensure an accurate oil level can be read while filling regardless of the oil temperature.