Grundfos KPL.700-1400 Operating instructions

Oil service kit
KPL.700-1400, KWM.700-1400
Service instructions
GRUNDFOS INSTRUCTIONS

English (GB)
2
English (GB) Service instructions
Original service instructions.
CONTENTS
Page
1. General information
These service instructions describe how to change oil in KPL
axial-flow propeller pumps and KWM mixed-flow impeller pumps
installed in column pipes with diameters from DN 700 to 1400.
For instructions on how to change oil in KPL and KWM pumps
with column pipe diameters from DN 500 to 650 or for more
general service instructions, see the KPL, KWM service
instructions, product number 98383809, available in the Grundfos
Product Center on Grundfos' homepage, www.grundfos.com.
1.1 Symbols used in this document
2. Safety
1. General information 2
1.1 Symbols used in this document 2
2. Safety 2
3. Oil service kit, KPL.700-800 and KWM.700-800 3
3.1 Assembling the oil pipe 3
3.2 Draining the oil 5
3.3 Filling oil 6
3.4 Checking the oil level 7
4. Oil service kit, KPL.900-1400 and KWM.900-1400 9
4.1 Assembling the oil pipe 9
4.2 Draining the oil 10
4.3 Filling oil 11
4.4 Checking the oil level 12
5. Oil quantity 12
5.1 Oil quantity according to column pipe diameter 12
Warning
If these safety instructions are not observed,
it may result in personal injury.
Warning
During electrical installation, make sure that the
power supply cannot be accidentally switched
on.
Warning
These instructions must be observed for
explosion-proof pumps. We recommend that you
also follow these instructions for standard
pumps.
Caution
If these safety instructions are not observed, it
may result in malfunction or damage to the
equipment.
Note
Notes or instructions that make the job easier
and ensure safe operation.
Warning
Make sure that the mains switch can be locked in
the 0/Off position. Type and requirements must
comply with EN 60204-1, 5.3.2.
Warning
Observe local regulations setting limits for
manual lifting or handling.
Warning
For safety reasons, all work in pump pits must be
supervised by a person outside the pit.
Warning
Pits for submersible wastewater pumps contain
wastewater potentially with toxic and/or
disease-causing substances.
Therefore, while working on the pump, wear
appropriate personal protective equipment and
clothing. In addition, carry out work on or near
the pump under strict observance of the hygiene
regulations in force.

English (GB)
3
3. Oil service kit, KPL.700-800 and KWM.700-800
3.1 Assembling the oil pipe
Fig. 1 Oil service kit, KPL.700-800 and KWM.700-800
Where nothing else is indicated, the position numbers refer to fig.
1and/or the figure below each step.
1. Connect the handle (pos. 24) to the rod (pos. 12).
2. Connect the intermediate pipe (pos. 10) to the barrel nipple
(pos. 16).
3. Connect the handle with rod (pos. A and step 1) to the
intermediate pipe with barrel nipple (pos. B and step 2).
4. Connect the handle with rod and the intermediate pipe with
barrel nipple (pos. C) to the intermediate pipe (pos. 11).
5. Connect the isolating valve (pos. 2) to the three-way tee fitting
(pos. 14).
6. Connect the isolating valve (pos. 17) to the barrel nipple (pos.
7).
7. Connect the isolating valve with barrel nipple (pos. F and step
6) to the isolating valve with three-way tee fitting (pos. E and
step 5).
TM06 3181 5014
Pos. Description
1Airhose
2 Isolating valve
3 Isolating valve
4 Intermediate fitting
5 Hexagon key
6 Hexagon key
7 Barrel nipple
8 Hexagon key
9 Barrel nipple
10 Intermediate pipe
11 Intermediate pipe
12 Rod
13 Funnel
14 Three-way tee fitting
15 Elbow fitting
16 Barrel nipple
17 Isolating valve
18 Handle
19 Plug
20 Intermediate fittings
21 Stub
22 Stub
23 Air pump
24 Handle
25 Air plug
13
14
15
16
17
18
19
20
21
22
23
24
25
1
2
3
4
5
6
7
8
9
10
11
12
TM06 3182 5014TM06 3183 5014TM06 3184 5014TM06 3185 5014TM06 3186 5014TM06 3187 5014TM06 3188 5014
24 12
10 16
A
B
11
C
214
17 7
FE

English (GB)
4
8. Connect the handle with rod, the intermediate pipe with barrel
nipple and intermediate pipe (pos. D and step 4) to the
isolating valve with barrel nipple and three-way tee fitting
(pos. G and step 7).
9. Connect the plug (pos. 19).
The oil pipe is now completely assembled. See fig. 2.
Fig. 2 Assembled oil pipe, column pipe diameters DN
700-800
TM06 3189 5014TM06 3190 5014TM06 3191 5014
D
G
19
H

English (GB)
5
3.2 Draining the oil
Fig. 3 Sectional view, KPL.700-800 and KWM.700-800
1. Remove all the plugs (pos. 26, 27, 28 and 29).
Fig. 4 Draining oil, KPL.700-800, KWM.700-800
Where nothing else is indicated, the position numbers refer to fig.
4and/or the figure below each step.
2. Completely loosen the handle (pos. 24).
3. Close the isolating valves (pos. 17 and 31).
4. Insert the assembled oil pipe (pos. 35) in the lower oil plug
space (pos. 33).
5. Connect the intermediate fitting (fig. 1, pos. 20) to the air plug
(fig. 1, pos. 25).
6. Connect the stub (fig 1, pos. 21) to the intermediate fitting with
air plug (step 5). Fit the assembled component in the upper oil
plug space (pos. 32). See fig. 4.
7. Connect the stub (fig. 1, pos. 22) to the air pump (pos. 23).
8. Fit the air hose (pos. 1) between the air pump with stub (step
7) and the assembled stub, intermediate fitting and air plug
(step 6) fitted in the upper plug space (pos. 32).
9. Open the isolating valve (pos. 31).
10. Slowly tighten the handle (pos. 24) until the oil starts to flow.
11. Connect the air pump (pos. 23) to the power supply.
12. Drain the oil into an appropriate waste disposal container.
13. When the oil has been drained, disconnect the air pump (pos.
23) from the power supply.
14. Remove the assembled oil pipe (pos. 35) and the plug fitted in
the upper oil plug space (pos. 32).
TM06 3192 5014
Pos. Description
26 Upper casing plug
27 Lower casing plug
28 Upper oil plug
29 Lower oil plug
30 Non-return valve
TM06 3193 5014
Pos. Description
1Airhose
17 Isolating valve
23 Air pump
24 Handle
31 Isolating valve
32 Upper oil plug space
33 Lower oil plug space
34 Non-return valve
35 Assembled oil pipe
28
26
27
29
30
1
24
17
31 35
34
33
23
32
Waste
oil
TM06 3194 5014TM06 3195 5014TM06 3196 5014TM06 3197 5014
Note
Dispose of used oil in accordance with local
regulations.
2520
21
22
23
1

English (GB)
6
3.3 Filling oil
Fig. 5 Filling oil, KPL.700-800, KWM.700-800
Where nothing else is indicated, the position numbers refer to fig.
5and/or the figure below each step.
1. Disconnect the rod (fig. 1, pos. 12) from the handle (pos. 24).
2. Connect the handle (pos. 24) to the assembled oil pipe (pos.
35).
3. Disconnect the plug (fig. 1, pos. 19) from the four-way tee
fitting on the assembled oil pipe (pos. 35).
4. Connect the funnel (pos. 13) to the intermediate fitting (fig. 1,
pos. 4).
5. Connect the assembled funnel and fitting to the assembled oil
pipe (pos. 35).
6. Fit the assembled funnel, fitting and oil pipe (pos. 35) in the
upper casing plug space (pos. 36). See fig. 5.
7. Close the isolating valves (pos. 17 and 31).
8. Pour the recommended quantity of oil through the funnel (pos.
13). See section 5. Oil quantity.
9. After completing the oil filling, disconnect the assembled oil
pipe (pos. 35).
10. Refit the plugs (fig. 3, pos. 26 to 29).
TM06 3198 5014
Pos. Description
13 Funnel
17 Isolating valve
24 Handle
31 Isolating valve
32 Upper oil plug space
34 Non-return valve
35 Assembled oil pipe
36 Upper casing plug space
TM06 3199 5014TM06 3200 5014TM06 3201 5014
13
24
34
32
17
31
35
36
Oil
24 12
24 35
19
35
TM06 3202 5014TM06 3203 5014
Note
The non-return valve (pos. 34) prevents oil from
leaking.
Note
The air inside the oil chamber escapes through
the upper oil plug space (pos. 32) due to the
difference in diameter.
13 4

English (GB)
7
3.4 Checking the oil level
Fig. 6 Checking the oil level, KPL.700-800, KWM.700-800
Where nothing else is indicated, the position numbers refer to fig.
6and/or the figure below each step.
1. Connect the handle (pos. 24) to the rod (fig. 1, pos. 12).
2. Connect the handle (pos. 24) with rod (fig. 1, pos. 12) to the
assembled oil pipe (pos. 35).
3. Remove the funnel (fig. 1, pos. 13) with intermediate fitting
(fig. 1, pos. 4) from the assembled oil pipe (pos. 35).
4. Connect the plug (pos. 19) to the four-way tee fitting on the
assembled oil pipe (pos. 35).
TM06 3204 5014
Pos. Description
9 Intermediate fitting
15 Elbow fitting
17 Isolating valve
19 Plug
24 Handle
31 Isolating valve
33 Lower oil plug space
34 Non-return valve
35 Assembled oil pipe
37 Isolating valve
38 Sight glass
37
38
24 19 33
35 34
17
9
15
31
A
A
TM06 3205 5014TM06 3206 5014TM06 3207 5014TM06 3208 5014
24 12
35
13
35
19

English (GB)
8
5. Connect the elbow fitting (pos.15) to the intermediate fitting
(pos. 9).
6. Connect the sight glass (pos. 38) with isolating valve (fig. 1,
pos. 3) to the elbow fitting (pos. 15) with intermediate fitting
(pos. 9 and step 5).
7. Connect the sight glass (pos. 38) with isolating valve (fig. 1,
pos. 3) and fittings (pos. 15 and 9) to the isolating valve (pos.
17).
8. Completely loosen the handle (pos. 24).
9. Close the isolating valve (pos. 31). Fit the assembled oil pipe
(pos. 35) in the lower oil plug space (pos. 33). See fig. 6.
10. Open the isolating valves (pos. 17 and 37).
11. Slowly fasten the handle (pos. 24) until the oil level is visible
in the sight glass (pos. 38).
12. Wait until the oil level has stabilised.
13. Check the oil level marked "MIN" according to the pipe column
diameter. See fig. 6, detail A.
14. After the oil level check, loosen the handle (pos. 24) to close
the non-return valve (pos. 34).
15. Open the isolating valve (pos. 31), and drain the remaining oil
from the sight glass (pos. 38) into an appropriate waste
disposal container.
16. Disassemble the oil pipe and place it in the suitcase (fig. 1) for
storage.
17. Fit oil and casing plugs (fig. 3, pos. 26-29).
TM06 3209 5014TM06 3210 5014TM06 3211 5014
Note
Handle the sight glass (pos. 38) with care.
15 9
3

English (GB)
9
4. Oil service kit, KPL.900-1400 and
KWM.900-1400
4.1 Assembling the oil pipe
Fig. 7 Oil service kit, KPL.900-1400 and KWM.900-1400
Where nothing else is indicated, the position numbers refer to fig.
7and/or the figure below each step.
1. Connect the handle (pos. 18) to the rod (pos. 9).
2. Connect the intermediate pipe (pos. 8) to the oil pipe (pos.
12).
3. Connect the handle with rod (pos. A and step 1) to the
intermediate pipe with oil pipe (pos. B and step 2).
4. Connect the isolating valve (pos. 3) to the intermediate pipe
(pos. 10).
5. Connect the handle with rod and the intermediate pipe with oil
pipe (pos. C and step 3) to the assembled isolating valve and
intermediate pipe (pos. D and step 4).
6. Connect the plug (pos. 14) to the assembled handle, rod,
intermediate pipe, oil pipe, isolating valve and intermediate
pipe (pos. E and step 5).
The oil pipe is now completely assembled. See fig. 8.
Fig. 8 Assembled oil pipe, KPL.900-1400, KWM.900-1400
TM06 3212 5014
Pos. Description
1Airhose
2 Sight glass with fittings
3 Isolating valve
4 Hexagon key
5 Intermediate fitting
6 Hexagon key
7 Hexagon key
8 Intermediate pipe
9Rod
10 Intermediate pipe
11 Funnel
12 Oil pipe
13 Handle
14 Plug
15 Intermediate fitting
16 Stub
17 Stub
18 Handle
19 Air plug
20 Air pump
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
TM06 3213 5014TM06 3214 5014TM06 3215 5014TM06 3216 5014TM06 3217 5014TM06 3218 5014TM06 3219 5014
18
9
812
A
B
310
C
D
E14

English (GB)
10
4.2 Draining the oil
Fig. 9 Sectional view, KPL.900-1400 and KWM.900-1400
1. Remove all the plugs (pos. 21, 22, 23 and 24).
Fig. 10 Draining oil, KPL.900-1400, KWM.900-1400
Where nothing else is indicated, the position numbers refer to fig.
10 and/or the figure below each step.
2. Completely loosen the handle (pos. 18).
3. Close the isolating valve (pos. 26).
4. Insert the assembled oil pipe (pos. 27) in the lower oil plug
space (pos. 29).
5. Connect the intermediate fitting (fig. 7, pos. 15) to the air plug
(fig. 7, pos. 19).
6. Connect the stub (fig. 7, pos. 16) to the intermediate fitting
with air plug (step 5). Fit the assembled component in the
upper oil plug space (pos. 28). See fig. 10.
7. Connect the stub (fig. 7, pos. 17) to the air pump (pos. 20).
8. Fit the air hose (pos. 1) between the air pump with stub (step
7) and the assembled stub, intermediate fitting and air plug
(step 6), fitted in the upper oil plug space (pos. 28). See fig.
10.
9. Open the isolating valve (pos. 26).
10. Slowly tighten the handle (pos. 18) until the oil starts to flow.
Make sure that the non-return valve (pos. 25) has been
activated when resistance is met.
11. Connect the air pump (pos. 20) to the power supply.
12. Drain the oil into an appropriate waste disposal container.
13. When the oil has been drained, disconnect the air pump (pos.
20) from the power supply.
14. Remove the assembled oil pipe (pos. 27) and the plug fitted in
the upper oil plug space (pos. 28).
TM06 3220 5014
Pos. Description
21 Upper casing plug
22 Lower casing plug
23 Upper oil plug
24 Lower oil plug
25 Non-return valve
TM06 3221 5014
Pos. Description
1Airhose
18 Handle
20 Air pump
25 Non-return valve
26 Isolating valve
27 Assembled oil pipe
28 Upper oil plug space
29 Lower oil plug space
21 23
24 25
22
20 1
28
25
2927
26
18
Waste
oil
TM06 3222 5014TM06 3223 5014TM06 3224 5014TM06 3225 5014
1915
16
17
20
1